TM - 9 - 2355 - 320 - 10 - RG33L Plus

TM 9-2355-320-10
OPERATOR MANUAL
COMMERCIAL OFF-THE-SHELF (COTS)
for
MINE RESISTANT ARMOR PROTECTED (MRAP PLUS)
VEHICLES
MRAP RG33L PLUS

2355-01-562-6675
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve
procedures, please let us know. Mail comments directly to: PM-MRAP, AMSTA-LC-GMM,
6501 E. 11 Mile Road, Warren, MI 48397-5000.
MANUFACTURED BY BAE SYSTEMS LAND AND ARMAMENTS GROUND SYSTEMS
Copyright © 2007 by BAE Systems Land & Armaments Ground Systems. All rights reserved.
DISTRIBUTION STATEMENT C: Distribution authorized to US Government agencies and their contractors; proprietary
information. Other requests for this document shall be referred to PM-MRAPS.
29 August 2008
TM 9-2355-320-10
WARNING SUMMARY
WARNINGS, CAUTIONS and NOTES

Read and observe all WARNING, CAUTION, and NOTE alert messages in this publication. They provide
information that can help prevent serious personal injury, damage to components, or both.
WARNING
WARNINGS are presented in BOLD type and may result in serious injury or death to personnel.
CAUTION
CAUTIONS are presented in BOLD type, following WARNINGS, and may result in damage to
equipment.
NOTE
NOTES are presented in BOLD type, following WARNINGS and CAUTIONS, and are general
statements.
a
TM 9-2355-320-10
WARNING
Carbon monoxide is a colorless, odorless, deadly poisonous gas, which, when breathed,
deprives the body of oxygen and causes suffocation. Exposure to carbon monoxide produces
headache, dizziness, loss of muscular control, drowsiness, and coma. Permanent brain damage
or death can result from severe exposure.
Carbon monoxide occurs in the exhaust of fuel-burning heaters and internal-combustion

engines and becomes dangerously concentrated under conditions of inadequate ventilation.
The following precautions must be observed to insure the safety of personnel whenever the
personnel heater, main, or auxiliary engine of any vehicle is operated for maintenance purposes
or tactical use.
THE BEST DEFENSE AGAINST CARBON MONOXIDE

POISONING IS ADEQUATE VENTILATION
1. DO NOT operate heater or engine of vehicle in an enclosed area unless it is ADEQUATELY

VENTILATED.
2. DO NOT idle engine for long periods without maintaining adequate ventilation in personnel
compartments.
3. DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors
removed unless necessary for maintenance purposes.
4. BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If
either are present, IMMEDIATELY VENTILATE personnel compartments. If symptoms persist,
remove affected personnel from vehicle and treat as follows: Expose to fresh air; keep warm;
do not permit physical exercise; if necessary, administer artificial respiration. For detailed first
aid instruction consult FM 4-25.11, First Aid for Soldiers.
WARNING
Chemical Agent Resistant Coating (CARC) paint contains isocyanate (HDI) which is highly
irritating to skin and respiratory system. High concentrations of HDI can produce symptoms of
itching and reddening of skin, a burning sensation in throat and nose, and watering of the eyes.
In extreme concentrations, HDI can cause cough, shortness of breath, pain during respiration,
increased sputum production, and chest tightness. The following precautions must be taken
whenever using CARC paint:
ALWAYS use air line respirators when using CARC paint unless air sampling shows exposure
to be below hazardous level threshold standards. Use chemical cartridge respirator, if air
sampling is above standards.
DO NOT allow skin or eyes to come in contact with CARC paint. Always wear protective
equipment (gloves, ventilation mask, safety goggles, etc).
DO NOT use CARC paint without adequate ventilation.
NEVER weld or cut CARC coated materials.
DO NOT grind or sand painted equipment without high-efficiency air purifying respirators in
use.
BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after initial
exposure. Seek medical help immediately if symptoms are detected.
b
TM 9-2355-320-10
WARNING
Lead-acid gases can explode. Do not smoke, have open flames, or make sparks around a
battery, especially if caps are off. If a battery is gassing, it can explode and cause injury to
personnel. Ventilate when charging or using in a enclosed space. Wear safety goggles and
acid-proof gloves when battery cover must be removed or when adding electrolyte. Avoid
electrolyte contact with skin, eyes, or clothing. If battery electrolyte spills, take immediate
action to stop burning effects:
External: Immediately flush with cold running water to remove all acid.
Eyes: Flush with cold water for at least 15 minutes. Seek immediate medical attention.
Internal: Drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Seek immediate medical attention.
Clothing or Vehicle: Wash at once with cold water. Neutralize with baking soda or household
ammonia solution.
WARNING
Wear double hearing protection when operating vehicle. Double hearing protection consists of
wearing earplugs or earmuffs with either an attenuating Combat Vehicle Crewmember (CVC)
helmet or headset. Failure to wear hearing protection can result in hearing damage.
WARNING
Always use “three point contact” with vehicle; face vehicle when entering or leaving cab. Three
point contact means that three out of four arms and legs are in contact with the vehicle at all
times during mount or dismount. Use ladders when conducting maintenance. Failure may
result in injury to personnel.
Clean shoes and wipe hands before climbing onto vehicle and use grab handles. Failure to
comply may result in injury to personnel.
Never use control levers as a hand-hold when climbing on or off. Never step on foot controls
when mounting or climbing off vehicle. Failure to comply may result in injury or DEATH to
personnel.
Never enter a moving vehicle. Failure to comply may result in injury or DEATH to personnel.
Do not use equipment for purpose other than its intended use, unless authorized by the
National Inventory Control Point (NICP)/commodity command. Failure to comply may result in
injury to personnel or equipment damage.
WARNING
Vehicle on jack could fall and injure you. Use jack stands when jacking vehicle.
c
TM 9-2355-320-10
WARNING
Compressed air can injure you. Do not aim compressed air at yourself or other personnel.
Always wear goggles when working with compressed air. Do not use more pressure than 30
psi (207 kPa) with air nozzles.
WARNING
Personnel may be exposed to RF radiation. Shut off radios prior to working around or touching
the antennas.
WARNING
Contact with energized electric circuits can kill or seriously injure personnel. Disconnect
battery ground cables when working on electrical system. Remove rings and jewelry.
WARNING
Hot parts can burn you. Allow parts to cool before working on or near them. If necessary, use
heat protective gloves to work on hot parts.
WARNING
Fire suppression agent can irritate your throat and eyes. Prolonged exposure can make you
dizzy. After discharging fire suppression system, open hatch covers and turn on vent fans, or
get all personnel out of vehicle as soon as possible.
WARNING
Hot coolant can burn you. Do not remove radiator cap until coolant temperature gauge reads in
bottom one-quarter of green zone. Use heat protective mittens to turn radiator cap. Turn cap
slowly to release pressure.
WARNING
Rotating parts can move suddenly and can pinch or crush hands. Keep guards in place. Keep
clear of rotating parts.
Do not operate vehicle with low air pressure. Vehicle brakes will not work. Ensure air pressure
gauge remains in normal operating range. Rapid, repeated operation of the brakes may deplete
compressed air reservoirs. Loss of air pressure will cause the emergency brakes to engage.
Failure to comply may result in injury to personnel or damage to equipment.
d
TM 9-2355-320-10
WARNING
Noise from firing weapons can permanently damage hearing. All personnel in or near vehicle
must wear double hearing protection when guns are fired.
WARNING
Accidental discharge of fire bottles can seriously injure you. Deactivate fire suppression
system before you work near fire bottles. Remove and cap squib.
WARNING
Accidental discharge of fire bottles can injure you. Remove vehicle ground cable when
maintaining fire suppression system.
WARNING
Accidental discharge of fire bottles can seriously injure your eyes or skin. Wear face shield, ear
plugs, protective clothing, and gloves during fire bottle maintenance.
WARNING
Tire or rim failure during tire inflation may cause personnel injury or death. Use tire cages.
WARNING
Weapon mount can fail, leading to rounds impacting incorrect target location. Check the
weapon mount for cracks and loose, broken, or missing parts prior to operation.
WARNING
Weapon and weapon station can seriously injure personnel. Make sure personnel and stowed
equipment are clear of weapon path before firing.
WARNING
Personnel can be struck by low hanging obstacles when standing in open hatch when vehicle is
moving. Keep hatches closed or in popped position when operating in areas with low-hanging
obstacles.
WARNING
Personnel can be struck by rocks, mud, or other debris kicked up by the vehicle tires, or other
vehicles when standing in open hatch. Wear helmets and eye protection.
e
TM 9-2355-320-10
WARNING
Vehicle motion can throw you from your seat and injure you. Wear seat belts at all times.
WARNING
Failure of air lines or air supply may cause vehicle brakes to lock up. Inspect air lines for
damage. Check air pressure gauge.
WARNING
Engine fan can blow away fire suppression agent before fire is extinguished. Personnel can get
burned. Equipment can get damaged. Stop engine before you operate engine fire suppression
system.
WARNING
Flammable materials can burn. Do not store flammable materials in crew compartment.
WARNING
Oily rags stored in engine compartment may cause fire. Do not store oily rags in the engine
compartment.
WARNING
Brakes can catch fire. Keep brakes clean of flammable materials.
WARNING
Fuel leaks may catch on fire. Check for leaks. Repair all leaks before operating.
WARNING
Inadequate air pressure may lead to tire fire. Check and adjust tire pressures prior to
operations.
WARNING
Damaged wiring could result in a fire. Check wiring for signs of damage prior to operations.
WARNING
Clean up all fluid spills. Spills can create slip and fire hazards. Dispose of materials in
accordance with local hazardous waste disposal procedures. Failure to comply may result in
injury to personnel and damage to the environment.
f
TM 9-2355-320-10
WARNING
Stowed items can block fire suppression system outlets and prevent fires from being put out.
Fire can kill or seriously injure personnel. Equipment can be damaged. Ensure stowed items
are kept clear of fire suppression system outlets.
WARNING
Fire in the crew compartment can kill or seriously injure personnel. Equipment can be
damaged. Exit the vehicle in the event of a fire as the tactical situation permits.
WARNING
Operating vehicle in hot weather increases risk of heat injury. Heat injury impairs performance
and can lead to injury. Drink lots of water. Work and rest in shade when possible. Follow
instructions in FM-21-10.
WARNING
Do not make seat adjustments while driving. You can crash.
WARNING
Control failures can cause vehicle to crash. A crash can kill or seriously injure personnel.
Check all controls for smooth operation. Do not drive vehicle if accelerator, steering, or brake
controls bind, or fail to return when released. Do not operate vehicle if engine does not return
to idle when accelerator pedal is released.
WARNING
Failure of a suspension or steering component may cause collision. Inspect steering and
suspension components and function prior to operation.
WARNING
Vehicle may impact objects, personnel, or other vehicles while backing. Use ground guides.
WARNING
Vehicle has high center of gravity. You can roll over. Slow for turns. Drive straight up or down
slopes when possible. Avoid traversing side slopes.
WARNING
Wheel may be lost from vehicle resulting in loss of vehicle control/ rollover. Torque lug nuts
per Maintenance section, Chapter 5.
g
TM 9-2355-320-10
WARNING
Low tire air pressure may lead to tire failure. You can lose control of vehicle or rollover. Check
tires for proper inflation prior to operation.
WARNING
Side and rear doors are very heavy (1,400 lb [636 kg] each). Keep away from the immediate area
behind and beside doors when operating door assist system. Be sure all hands and feet are
clear of doors before closing. Failure to comply with this warning could result in damage to
equipment and serious injury or death to personnel.
WARNING
Always wear a respirator, gloves, protective goggles, and protective clothing when working on
the AFSS system. If exposed to FM 200 without protective gear, seek immediate medical
attention. Failure to comply with this warning could cause serious injury or death to personnel.
WARNING
Closing hatch can crush hands or feet. Use handle to open or close hatch. Be sure all hands
and feet are clear of hatch rim before closing. Verify hatch is in the locked position when open.
Failure to comply with this warning could result in damage to equipment and serious injury or
death to personnel.
WARNING
Do not rely on the parking brake on steep slopes. Use wheel chocks when necessary.
WARNING
Diesel fuel is flammable. Wipe up fuel spills immediately. Shut off engine when fueling, and do
not overfill tank. Do not smoke during fueling operations. Avoid operating electrical equipment
such as radios and personnel heaters while fueling. Failure to comply with this warning could
cause explosions and fire and cause serious injury or death to personnel or damage to
equipment.
WARNING
Doors are very heavy (1,400 lb [636 kg]) each and difficult to operate without power assist. Get
an assistant to help or use a suitable lifting device when operating doors without power assist.
WARNING
Do not put hands near pintle hook when aligning lunette eye with pintle hook. Failure to comply
may result in crushed hands or fingers.
h
TM 9-2355-320-10
WARNING
The tow bar is heavy and requires a two-person lift. The tow bar is mounted approximately 3 ft
(1 m) off the ground. Additionally, it is set back from the front of the vehicle. Care must be
exercised when dismounting the tow bar to avoid serious injury or damage to equipment.
WARNING
Personnel may be exposed to toxic materials during maintenance. Wear gloves and eye
protection to prevent injury.
WARNING
Air system operates at 120 psi (828 kPa). This pressure will damage eyes and cause bodily
injury. Always drain air tanks before working on any part of air system. Leave system open
until work is complete to prevent accidental charging. Failure to comply may result in severe
injury or death to personnel.
Do not operate vehicle with low air pressure. Vehicle brakes will not work. Ensure air pressure
gauge remains in normal operating range. Rapid, repeated operation of the brakes may deplete
compressed air reservoirs. Loss of air pressure will cause the emergency brakes to engage.
Failure to comply may result in injury to personnel or damage to equipment.
WARNING
Anti-corrosion compound is toxic. Use only in a well-ventilated area. Use NIOSH/MSHA-

approved respirator with dual organic vapor/mist and particulate cartridge. Wear chemical
safety goggles and full face shield when using. Avoid contact with skin and wear rubber or
plastic gloves. In case of contact, remove contaminated clothing and immediately wash area
with soap and water. If eyes are contaminated, flush with large amounts of water for at least 15
minutes and get immediate medical attention. If swallowed, DO NOT INDUCE VOMITING;
contact a physician immediately. Failure to comply may result in serious injury or death to
personnel.
WARNING
• Clean up all fluid spills. Spills can create slip and fire hazards. Dispose of materials in
accordance with local hazardous waste disposal procedures. Failure to comply may result
in injury to personnel and damage the environment.
• Oily rags stored in engine compartment may cause fire. Do not store oily rags in the
engine compartment.
• Fuel leaks may catch on fire. Check for leaks. Repair all leaks before operating.
• Flammable materials can burn. Do not store flammable materials in crew compartment.
i/j blank
TM 9-2355-320-10
OPERATOR MANUAL
COMMERCIAL OFF-THE-SHELF (COTS)
for
RG33L PLUS
MINE RESISTANT
VEHICLES
RG33L PLUS
2355-01-562-6675
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve
procedures, please let us know. Mail comments directly to: PM-MRAP, AMSTA-LC-GMM,
6501 E. 11 Mile Road, Warren, MI 48397-5000.
27 August 2008
TM 9-2355-320-10
TABLE OF CONTENTS
WARNING SUMMARY
HOW TO USE THIS MANUAL
CHAPTER ONE - GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
General Information, Equipment Description and Theory of Operation.................................................................. 1-1
List of Abbreviations................................................................................................................................................ 1-2
CHAPTER TWO - OPERATOR INSTRUCTIONS
Operate Parking Brake/Trailer Air Supply Control .................................................................................................. 2-1
Master Power and Off/Run/Start Switches ............................................................................................................. 2-2
Engine Start Procedures ......................................................................................................................................... 2-3
Transmission Shift Selection................................................................................................................................... 2-4
Drive Vehicle ........................................................................................................................................................... 2-6
Stop Engine............................................................................................................................................................. 2-8
Steering Column Controls ....................................................................................................................................... 2-9
Operate Hatches ................................................................................................................................................... 2-10
Operate Turret Hatch Cover.................................................................................................................................. 2-12
Operate Side Door Assist...................................................................................................................................... 2-13
Operate Rear Door................................................................................................................................................ 2-15
Adjust Seat Travel................................................................................................................................................. 2-17
Adjust Seat Back................................................................................................................................................... 2-17
Operate All Wheel Drive (AWD) and Transfer Case (T-Case) Selector Switches................................................ 2-18
Operate Left and Right Scene Light Switches ...................................................................................................... 2-20
Operate Windshield Wipers .................................................................................................................................. 2-20
Operate Interior Lights .......................................................................................................................................... 2-21
Operate Golight..................................................................................................................................................... 2-22
Heating System Operation .................................................................................................................................... 2-23
Starting Heater ...................................................................................................................................................... 2-24
Heater Shutdown .................................................................................................................................................. 2-25
Heater Operation Faults........................................................................................................................................ 2-25
Operate Air Conditioning and Ventilation System................................................................................................. 2-27
Operate Defroster ................................................................................................................................................. 2-28
Air Cleaner ............................................................................................................................................................ 2-29
Engine Exhaust Braking Control ........................................................................................................................... 2-30
Operate Automatic Fire Suppression (AFSS) ....................................................................................................... 2-31
Activation of Crew Compartment AFSS................................................................................................................ 2-33
External Emergency Fire Extinguisher Switch ...................................................................................................... 2-34
Fuel Vehicle .......................................................................................................................................................... 2-35
Stow/Unstow Fuel and Water Cans ...................................................................................................................... 2-37
Raise Hood ........................................................................................................................................................... 2-38
Lock and Unlock Stowage Bins ............................................................................................................................ 2-39
Stow Squad Seat .................................................................................................................................................. 2-40
Rifle Rack .............................................................................................................................................................. 2-41
Operating Under Unusual Conditions ................................................................................................................... 2-42
Runflat ................................................................................................................................................................... 2-42
Mud, Sand and Snow............................................................................................................................................ 2-43
Unusual Terrain..................................................................................................................................................... 2-44
Fording .................................................................................................................................................................. 2-46
Rear Door Emergency Operation ......................................................................................................................... 2-48
Resetting Power Assist System ............................................................................................................................ 2-50
Emergency Evacuation ......................................................................................................................................... 2-51
Stow/Unstow Tow Bar........................................................................................................................................... 2-52
CASEVAC and Litter Deployment......................................................................................................................... 2-53
Start Vehicle with Outside Power Source ............................................................................................................. 2-60
Preparing Disabled Vehicle for Towing Operations .............................................................................................. 2-62
i
TM 9-2355-320-10
TABLE OF CONTENTS - CONTINUED
CHAPTER THREE - TROUBLE SHOOT PROCEDURES
Introduction to Troubleshooting............................................................................................................................... 3-1
Troubleshooting Symptom Index ............................................................................................................................ 3-3
Troubleshooting Tables........................................................................................................................................... 3-5
CHAPTER FOUR - PMCS MAINTENANCE INSTRUCTIONS
Preventive Maintenance Checks and Services (PMCS)......................................................................................... 4-1
CHAPTER FIVE - MAINTENANCE INSTRUCTIONS
General.................................................................................................................................................................... 5-1
Jacking Vehicle ....................................................................................................................................................... 5-2
Replace Front Wheel/Tire ....................................................................................................................................... 5-3
Replace Fuel Filler Neck Strainer ........................................................................................................................... 5-5
Replace Air Cleaner Filter ....................................................................................................................................... 5-7
Replace Hull Drain Plug .......................................................................................................................................... 5-9
Drain Air Tanks .....................................................................................................................................................5-10
Rear Spring Brake Caging ....................................................................................................................................5-11
Rear Spring Brake Uncaging ................................................................................................................................5-12
Lubrication Instructions .........................................................................................................................................5-13
CHAPTER SIX - SUPPORTING INFORMATION
BII Listing................................................................................................................................................................. 6-1
Expendable and Durable Items List ........................................................................................................................ 6-4
ii
TM 9-2355-320-10
TABLE OF CONTENTS - CONTINUED
HOW TO USE THIS MANUAL
This manual contains instructions for safe and efficient operation of the Mine Resistant Ambush Protective
(MRAP) RG33L Plus manufactured by BAE Systems, Land and Armaments.
This manual has six chapters that contain sections with alpha/numeric pages. Use the table of contents for
reference and quick access.
There are three types of notations: Warnings- are posted in the summary and prior to text that cover any area that
would present a situation that may result in injury or death, compliance is mandatory. Cautions- will be found on
the same page and preceding the text covering any area that would present a situation that may result in damage
to equipment. Notes - will precede text to alter normal procedures or point out areas of concern.
The manual consists of:
Front Matter - a cover page, copyright release statement, warning summary, how to use this manual, and
recommended manual improvements.
Chapter 1 - provides General Information, Equipment Description, and Theory of Operation.
Chapter 2 - contains Operator Instructions.
Chapter 3 - provides Troubleshooting Procedures for operator/crew.
Chapter 4 - contains Preventive Maintenance Checks and Services (PMCS) instructions for Before, During, After,
Weekly, and Monthly checks.
Chapter 5 - provides Maintenance Instructions for the Operator to include Lubrication Instructions.
Chapter 6 - contains Supporting Information. This chapter lists expendable and durable items and Basic Issue
Items (BII) for the RG33L Plus Family of Vehicles to help you inventory the items for safe and efficient operation
of the equipment.
iii/iv blank
TM 9-2355-320-10
CHAPTER 1 – GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY
OF OPERATION
GENERAL INFORMATION
SCOPE
This COTS manual for the MRAP RG33L Plus, Category II family of vehicles contains instructions for the
operation of the vehicle, Preventative Maintenance Checks and Services (PMCS), operator troubleshooting
procedures, and maintenance instructions.
MAINTENANCE FORMS AND PROCEDURES
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 738-750, Functional Users Manual for The Army Maintenance Management System
(TAMMS).
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your vehicle needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us
what you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on an
SF 368 (Product Quality Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-Automotive and
Armaments Command, ATTN: AMSTA-LC-GMM, Warren, MI 48397-5000. We’ll send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
A corrosive environment includes exposure to high humidity, salt spray, road de-icing chemicals, gravel damage,
and atmospheric contamination. No action beyond normal washing and repair of damaged areas is needed to
control corrosion. To prevent moisture accumulation, drain holes are provided on structural and sheet metal
areas where needed, and stowage boxes are provided with seals and baffled drains.
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with the vehicle be reported so that the problem can be corrected and improvements made to
prevent the problem in future items.
While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials,
such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a
corrosion problem.
If a corrosion problem is identified, it can be reported using form SF 368 (Product Quality Deficiency Report). Use
of key words such as "corrosion," "rust," "deterioration,” or "cracking,” will ensure that the information is identified
as a CPC problem.
The form should be submitted to the address specified: Commander, U.S. Army Tank-Automotive and
Armaments Command, ATTN: AMSTA-LC-GMM, Warren, MI 48397-5000.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
Command decision, according to the tactical situation, will determine when the using organization is to destroy a
vehicle. A destruction plan will be prepared by the using organization, unless one was prepared by a higher
authority. For general vehicle destruction procedures, refer to TM 750-244-6, Procedures for Destruction of Tank-
Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive and Armaments Command).
1-1
TM 9-2355-320-10
OF OPERATION - CONTINUED
LIST OF ABBREVIATIONS
°F Degree Fahrenheit
°C Degrees Celsius
AAL Additional Authorized List
A/C Air Conditioning
AFSS Automatic Fire Suppression System
AOAP Army Oil Analysis Program
ATE Automatic Test Equipment
AWD All Wheel Drive
BII Basic Issue Item
BIT Built–In–Test
BITE Built–In–Test Equipment
BTU/hr British Thermal Units/hour
CAGEC Contract and Government Entity Code
CAR Corrective Action Report
CARC Chemical Agent Resistant Coating
CCW Counterclockwise
CFM Cubic feet per minute
CHG Charge
CLR Clear
CM Centimeters
CMM Cubic Meters per Minute
CMD Command
Cm HG Centimeters of Mercury
COTS Commercial Off-The_Shelf
COEI Component Of End Item
CPC Corrosion Prevention and Control
CTA Common Table of Allowances
CW Clockwise
D Drive
DC Direct Current
DF Diesel Fuel
DGRD Degraded
DIA Diameter
DOD Department of Defense
DS Direct Support
ECS Environment Control System
ECU Electronic Control Unit
EFP Explosively Formed Projectile
1-2
TM 9-2355-320-10
LIST OF ABBREVIATIONS - CONTINUED

EHA Electrohydrostatic Actuator
EOP Engine Oil Pressure
FES Fire Extinguishing System
FFCS Full Function Crew Station
FMC Fully Mission Capable
FOV Family of Vehicles
FRH Fire Resistant, Rust Inhibited Hydraulic Fluid
ft Foot/Feet
FWD Forward
GFE Government Furnished Equipment
GND Ground
GPL Gallons per Liter
GPM Gallons per Minute
GPS Global Positioning System
GS General Support
HG Mercury (vacuum measurement)
HR Hand Receipt
hr Hour
IAW In accordance with
IED Improvised explosive device
in. inch
In.-Hg Inches of Mercury
in-lb inch-pound
KG Kilogram
KMPH Kilometers Per Hour
kPa Kilopascals
KPH Kilometer Per Hour
kW Kilowatts
L Liter
LB Pound
LB-FT Pounds of Force per Foot
LCD Liquid Crystal Display
LED Light Emitting Diode
LHR Low Heat Rejection
LRSO Local Radiological Safety Officer
m Meter
M/S Meters Per Second
1-3
TM 9-2355-320-10
LIST OF ABBREVIATIONS - CONTINUED

MAC Maintenance Allocation Chart
MAX Maximum
MIN Minimum
MM Milimeter
MOS Military Occupational Specialties
MPH Miles Per Hour
MRAP Mine Resistant Ambush Protective
mt Metric Ton
N Neutral
N•m Newton-meters
NAV Navigation
NBC Nuclear, Biological, Chemical
NSN National Stock Number
P Park
PDC Power Distribution Center
PEG Polyethylene glycol
PMCS Preventative Maintenance Checks and Services
PRV Pressure Relief Valve
PSI Pounds Per Square Inch
PTO Power Take Off
PWR Power
QA Quality Assurance
QDR Quality Deficiency Report
R Reverse
RPM Revolutions Per Minute
RPSTL Repair Parts and Special Tools List
SE Support Equipment
STE Special Test Equipment
STE/ICE-R Simplified Test Equipment for Internal Combustion
TEV Thermostatic Expansion Valve
TM Technical Manual
TMDE Test, Measurement, Diagnostic Equipment
T-CASE Transfer Case
VDB Vehicle Distribution Box
VDC Volts Direct Current
WP Work Package
1-4
TM 9-2355-320-10
INTRODUCTION
This section contains the description and specifications for the MRAP RG33L Plus, Category II vehicles.
Physical Description
The MRAP RG33L Plus, Category II vehicle is required to increase survivability and mobility of occupants
operating in a hazardous fire area against known threats such as small arms fire, rocket propelled grenades, and
improvised explosive devices. MRAP vehicles are armored with a blast resistant underbody designed to protect
crew from mine blasts, fragmentary and direct fire weapons. Category II vehicles provide a reconfigurable vehicle
that is capable of supporting multi-mission operations such as convoy lead, troop transport, Explosive Ordnance
Disposal (EOD), and combat engineering. The vehicle will provide deployed commanders, various units,
Explosive Ordnance Disposal and Combat Engineer teams with survivable ground mobility platforms.
BATTERIES
BATTERIES
WATER AND FUEL STORAGE BOX

TOW BAR
The all-welded monocoque (no frame rail) hull is manufactured from several high-strength alloy steels to defeat
the given threat. The hull is supported by beam axles both front and rear. The powertrain consists of a Cummins
ISLE 8.9 Litre 450 diesel engine coupled to an Allison 3200SP six-speed automatic transmission. A Cushman
315M-1 transfer gearbox is in line with the transmission and provides drives for the front and rear axles. The
driveline is depicted in the following illustration.
2
3
A propshaft transfers the drive from the transmission to the transfer gearbox. Drive is then transferred from the
transfer gearbox by propshafts to the front axle (1), the intermediate axle (2), and then, on the CAT II only, from
the intermediate axle (2) to the rear axle (3). Operator controls consist of brake and accelerator foot pedals, a
steering wheel and a shift selector for operating the automatic transmission. Controls for the transfer gearbox
range select and the parking/trailer brakes are also in the driver’s area. Other controls include the side and rear
door assists, driver’s instrument panel, automatic fire suppression panel and heater/AC controls. The vehicle
distribution box is part of the Power Distribution Center (PDC) and is incorporated into the redesigned center
console of the dashboard. Command/control equipment is located on a digi-rack behind the driver’s seat.
1-5
TM 9-2355-320-10
MRAP RG33L Plus Category II Specification
PARAMETER VALUE
Length CAT II 337 in. (856 cm)
Width 114.08 in. (290 cm)
with GPK 128 in. (325 cm)
Height
w/o GPK 105 in. (267 cm)
w/effector panels 66,119 lb (30, 018 kg)
Curb Weight
w/o effector panels 57,019 lb (25,887 kg)
Gross Vehicle Weight 73,500 lb (33,369 kg)
Maximum Road Speed ≥ 65 mph (105 kph) on paved 0% slope.
50% slope @ 2 mph (3 kph), 40% slope @ 4
Maximum Gradient
mph (6 kph), 5% @ 25 mph (40 kph)
Maximum Side Slope 30% @ 5 mph (8 kph)
Ground Clearance 14 in. (36 cm)
Vertical Obstacle 14 in. (36 cm) vertical step @ 0 to ± 30°
Fording Depth 36 in. (91 cm)
Turning Radius 33 ft (10 m) curb to curb
Approach Angle ≥ 40°
Departure Angle ≥ 42°
Configuration Rear wheel drive w/all wheel drive capability.
Cummins ISLE – 6 Cyl 450hp@ 2200-RPM
Engine
and 1200 lb-ft (1627 N•m) @ 1300 RPM.
Allison 3200SP, six forward speeds, one
Transmission reverse speed, Gen IV TCU w/push button
control.
Cushman 315M-1 series, 1.00:1 (hi) and
Transfer Gearbox
2.52:1 (low) ranges
Axle Tech 5000 Series – 25K rated w/ 5.60:1
Front Axle
hub reduction. 7.56:1 drive ratio.
Drive Thru Axle
Final Axle
Wheelbase – Axle #1 - #2 139 in. (353 cm)
Wheelbase – Axle #2 - #3 60 in. (152 cm)
Front Axle: Standens leaf spring
Suspension Mid and Rear Axle: Hendrickson walking
beam suspension
Monotube gas pressurized
Dampers Front Axle – 2 each per wheel station
Rear Axle – 1 each per wheel station
Air – Spring Applied Drum -
Brakes
Manual released emergency
1-6
TM 9-2355-320-10
MRAP RG33L Plus Category II Specification - Continued
PARAMETER VALUE
Tires Michelin 16.00 R20 XZL ‘M’ loaded
Wheels (Rims) w/Run Flats Titan w/Hutchinson VF-0223-C runflat
Electrical System 24 VDC
A/C System Technical Specifications Total unit cooling capacity: 66,000 BTU/hr
(33,000 BTU/hr per side)
Ambient design condition: 131F @ 10% RH
Refrigerant: R134a
Fan speed: 3
Total air flow per side: 600 CFM (17 CMM)
(max)
Power supply: 24 VDC
Weight (approx.): Evaporator unit ~ 70lb (32
kg)
Condenser unit: ~ 65lb (30 kg)
Condenser fan (6x) Type: Axial; Impeller diameter: 14 in. (35 cm)
Voltage: 24 VDC
Condenser Coil (2x) Pipe - work: 3/8” copper tubing
Flanges: 2.0 mm Galvanized steel
Fins: Aluminum
Heat rejection (per side): 64,000 BTU/hr
Evaporator fan (4x) Type: Centrifugal
Impeller diameter: 100 mm
Voltage: 24 VDC
Rated power: .3 kW
Evaporator Coil (2X) Pipe-work: 3/8” copper tubing
Flanges: 1.6 mm Galvanized steel
Fins: Aluminum
Hunter A20 Heater Rating: 60,000 BTU/hr
Rated Air Flow: 225 SCFM
Fuel: DF1, DF2 or DFA, and JP8
Fuel Efficiency: 0.50 gal. (1.8 l) per hour
Power Requirements: 478 Watts – 19.9 Amps
Max.
Operating Range: 19-30 VDC
EMI characteristics: MIL-STD-461A Notice 4,
Class 3A.
Length: 27 in. (67 cm)
Diameter: 8 in. (20 cm)
Weight: 38 lbs (97 cm)
Accessories included: Vent Seal gasket
Mobile Climate Control Defroster Heating: 53,000 BTU/hr (15.5 kW @100 °C
T.D. and 3.6 GPM)
Air Flow: 400 CFM (11 CMM)
Motor: 3 speed + OFF
1-7
TM 9-2355-320-10
Capacities Table
Item Specification
Engine Oil 29 qt (27 l): 15W40 (MIL-PRF-2104)
Cooling System – engine only 11.7 qt (11 l):
Extended Life Coolant (ELC)
Transmission with Filter – Dry 29 qt (27 l): 15W40 (MIL-PRF-2104)
Transmission with Filter – Drain and Refill 19 qt (18 l): 15W40 (MIL-PRF-2104)
Transfer Case Oil 14.5 qt (13.7 l): 15W40 (MIL-PRF-2104)
Axle Lubricant 14-18 qt (13-17 l): 80W90
Power Steering Fluid 14-15 qt (13-14 l): 15W40 (MIL-PRF-
2104)
A/C Refrigerant TBD: R134a
Fuel 80 gal. (303 l): JP-8
Driveshaft Sliding sections ≤ 30 grams: Lithium
complex soap PAO EP2
1-8
TM 9-2355-320-10
Hull Assembly
Hull Structure
The hull is a fully welded monocoque structure, manufactured from RHA Class II Steel with multiple sections.
General views of the hull structure are shown below.
1-9
TM 9-2355-320-10
Interior Lay-Out
The MRAP RG33L Plus vehicles are fitted to be an Infantry Tactical Maneuver Vehicle upon delivery. The 6x6
will also accommodate the mission equipment package for an Ambulance Vehicle. There is front and rear seating
for 8 squad members and driver’s/commander’s seats in front.
Exterior Lay-Out
The MRAP RG33L Plus is equipped with multiple external stowage boxes as well as external access to the
batteries (each side). The rear fuel tanks can be accessed externally, but only fueled from left tank. A roof ladder
is located next to the Driver’s door and there are two rear stowage boxes as well. There are two external mounts
for Water and Fuel Cans.
Batteries
Water and Fuel
Storage Box
1-10
TM 9-2355-320-10
Seats and Restraints
The seating arrangement in the MRAP RG33L Plus is front and rear for the squad with driver’s and commander’s
seats in the front cab. An overall seating arrangement is shown below.
Driver’s and Commander’s Seat

The Driver and Commander will utilize a Global Seating Systems COBRA seat.
1-11
TM 9-2355-320-10
Squad Seat
The squad seats incorporate a compressible link design for mine blast survivability. These seats are mounted via
a fixture to the side rails in the vehicle.
Seat Belts
Driver and Commander seat belts are 5-point belts. Squad seats are 4-point belts.
Powerpack
The powerpack consists of the following major components:

1. Diesel Engine
2. Transmission
3. Cooling System
The diesel engine, transmission, and cooling system are fitted to the MRAP RG33L Plus as a combined unit
installed thru the top and front of the vehicle. The entire unit can be removed quickly in the field.
1-12
TM 9-2355-320-10
Engine
The engine is a Cummins Model ISLe (8.9 L) 450 4-stroke, in-line six-cylinder, turbocharged diesel with air-to-air
aftercooling and electronic control.
Transmission
The transmission is an Allison Model 3200SP, six-speed unit with Gen IV Electronic Control Unit (ECU). The
3200SP has a single reverse gear ratio and is used primarily in commercial applications. The ECU is the primary
controlling component of this system. The ECU performs system diagnostic functions, logic-control for
transmission function, and fault detection.
Shift Selector
1. The transmission shift selector is of the pushbutton type and is mounted to the dash.
2. The shift selector has a MODE button, a MODE on indicator, a digital display, and range selection buttons.
a. The following transmission ranges can be selected: Reverse (R); Neutral (N); Drive (D); 1-6 (Ranges).
The digital display shows only one number or letter at a time. When range is selected, the digital display
indicates the selected range if the ECU determines the shift is acceptable.
b. The MODE feature may be used to change the shifting characteristics of the transmission or to activate
an operator requested input function. If the display is flashing, the shift is either temporarily or
permanently inhibited. The inhibit may clear if the cause of the inhibit clears within 3 seconds of the shift
request. Otherwise, the operator must re-select range.
c. The gear selector can be placed in Reverse; Neutral; Drive; 1-6 ranges.
d. If all LED segments are on for more than 12 seconds, the ECU has not completed initialization. A
diagnostic code is associated with this condition and must be cleared.
1-13
TM 9-2355-320-10
Shift Selector - Continued
3. Identify Gear Range Selection Push buttons as follows:
a. Neutral (N) is selected before starting and during engine idling. When selected, (N) appears on selector
window.
b. Reverse (R) is used to move the vehicle backwards. When selected, (R) appears on selector window.
c. Drive (D) is used most often. This includes all six forward ranges. When a drive gear range has been
selected, the transmission starts in first gear and as conditions permit, automatically up-shifts and down-
shifts as required.
Cooling System
The cooling system is designed as an integral part of the powerpack and removes the heat generated in the
engine combustion air, oil, and water and the transmission oil. The air compressor also has an integrated cooling
coil to dissipate heat to atmosphere. The cooling system consists of an engine coolant radiator (1), air/water
charge air cooler (2), engine oil cooler (3), transmission oil cooler (4), transfer case oil cooler (5) and an engine
driven, two speed fan (6). The critical temperatures for the engine are a maximum 225°F (107°C) with an ECM
feature that decreases engine power if the temperature exceeds 235°F (113°C). The transmission maximum
coolant temperature is 275°F (135°C) and the charge air cooler inlet manifold temperature shall be maintained
within 43°F (6°C) of ambient. The engine heat exchanger is of single-pass aluminum bar fin construction with 10
fins per inch. The heat exchanger is a single core with a face area of 6.4 sq-ft (.6 sq-m) and provides cooling to
the Cummins ISLe 450 engine and the Allison 3200SP transmission.
3
4
1-14
TM 9-2355-320-10
Variable Speed Fan Control
The fan is mounted to a variable speed, viscous coupling.
Thermostat
Then engine cooling system thermostat controls coolant flow throughout the engine. The thermostat is
mechanical and has a cracking/opening temperature of 180°F (82°C).
Surge Tank
The surge tank is mounted to the top of the engine and has a capacity of 2 gallons (7.5 L) of coolant. The tank
allows 5% of expansion and has a nominal working pressure of 15 psi (103 kPa).
Air Cleaner
The air cleaner is located below the right side forward door.
Steering Systems
The steering system consists of the following:
1. Power Steering Pump
2. Emergency Steer Pump
3. Axle Steering system
4. Power Steering Gear
5. Auxiliary Steering Gear
6. Steering Wheel
7. Change Over Valve
Power Steering Pump
The power steering pump is located on the engine bolted to the back side of the air compressor. The pump is
supplied by TRW and provides the required hydraulic pressure and flow for operating the power steering gear.
The flow of the system is 50 liters/min at 2300 psi.
Emergency Steer Pump
The emergency steer pump is a ground-driven pump connected to the transfer gear box and is supplied by
Cassappa. The emergency steer pump provides auxiliary hydraulic pressure and flow in the event of hydraulic
pressure loss or during vehicle towing.
Axle Steering System
The MRAP RG33L Plus incorporates a double cardan steering joint on the Axle Tech 5000 front axle. The
steering has a maximum cramp angle of 32°, a 7° king-pin inclination, 2° of camber, and 1/16 to 1/8 inch toe-in.
Power Steering Gearbox
The hydraulic power assisted steering gearbox is a TRW TAS-85. It is mounted to the lower left side of the
engine compartment and provides a 23.1:1 gear ratio and a maximum output torque of 58,850 lb-in. (58,850
N•m). This gearbox requires a pump flow of 4.2-8.0 GPM @ 2175 psi (max) for 1.5 hwt/sec (hand wheel turns).
Auxiliary Steering Gearbox
The MRAP RG33L Plus is equipped with a TRW RCS-85 rotary cylinder auxiliary steering gearbox. The auxiliary
steering gearbox assists the power steering gearbox in turning the wheels on the MRAP RG33L Plus.
Steering Column and Wheel
The position of the Douglas Autotech steering column can be adjusted in tilt and in/out positions. The diameter of
the wheel is 16 in. (41 cm).
1-15
TM 9-2355-320-10
Driveline
This section describes the driveline for the MRAP RG33L Plus vehicle. The figure shows the general layout of the
driveline. The driveline consists of the driveshaft (1), a transfer case (2), an intermediate prop shaft (3), a front
prop shaft (4), a front axle (5), an intermediate axle (6), an axle-to-axle propshaft (7), and a rear axle (8). All axles
include internal differentials.
1 2
6
3 8
4
5
7
AXLES
Final Drive
The final drive is used on rear axle (8). The final drive is an Axle Tech 5000 series non-steered, non-drive-thru
with a planetary hub reduction of 5.60:1. The capacity of the axle is 25,000 lb (11,340 kg) with a final drive ratio
of 7.56:1. The final drive axle contains an air-actuated locking differential controlled from the driver’s station.
Intermediate Axle
The intermediate drive axle (6) distributes the power from the transfer gear box to rear axle (8) and the wheel
hubs. The intermediate drive axle is a Axle-Tech series 5000 with a 7.56:1 drive thru ratio, a 5.68:1 axle ratio and
a capacity of 27,000 lb (12,247 kg). The planetary hub reduction is 5.60:1. The intermediate axle contains an air-
actuated locking differential controlled from the Driver’s station.
Front Axle
The front drive is an Axle Tech 5000 series steer axle with a planetary hub reduction of 4.00:1. The capacity of
the axle is 27,000 lb (12,247 kg) with a final drive ratio of 5.68:1. The front drive axle contains an air-actuated
locking differential controlled from the Driver’s station.
1-16
TM 9-2355-320-10
Axle to Axle Propshafts
The following axle-to-axle propshafts are used in the MRAP RG33L Plus driveline:
1. Transmission to transfer gear case input
2. Transfer case to front axle
3. Transfer case to intermediate axle
4. Intermediate axle to rear axle
3
4
Transfer Gear Box

The transfer gearbox is mounted to the hull structure and contains a high (1.00:1) and low (2.52:1) range. The
gearbox is a Cushman model 315M-1 two-speed, three-shaft case incorporating an internal oil pump and air-
actuated front axle disconnect.
T-Case shift
controls
Terrain Modes
Selection control located on the dash gives the operator a choice of three modes of vehicle operation.
4 x 6 Mode (General or On-Highway Mode)
This mode selection transfers power to the rear drive axles only. The front axle is disengaged through the
transfer gear case via a pneumatic control valve. Both sets of rear axles are then driven through their respective
differentials. While in this mode, torque is always applied to diagonal opposing wheels for full traction.
6 x 6 Mode (Grass – Gravel – Snow – Mud)
This mode selection transfers power to all of the drive axles. The rear axle power remains as noted in the 4x6
mode selection.
6 x 6 Mode with Differential Loc (Deep Snow, Sand & Mud)

This mode selection transfers power to all of the drive axles as well as engages the differential locks in the drive
axles. In this mode, all tires are locked together and provide maximum traction. This mode can only be selected
when the 6x6 mode is used. It cannot be operated in the 4x6 mode.
1-17
TM 9-2355-320-10
Tow Mode
This mode selection will disengage the transfer gear case to the driveshaft outputs for both front and rear so that
the vehicle can be towed without the need to disconnect the driveshafts.
SUSPENSION
Springs
The front suspension system used on the MRAP RG33L Plus consists of leaf-type springs supporting the axles
with damping units at each wheel station as shown below.
The front springs (1) are a Standens design with a spring rate of 2430 lbs/in and a maximum load capacity of
25,000 lbs. The rear suspension (2) is a Hendricks on walking beam design with a maximum load capacity of
52,000 lbs.
3 2
FRONT REAR
Shocks
The shocks (3) are standard monotube gas pressurized system.
Bump Stops
A simple elastomer bump stop (4) is utilized on the front leaf springs. The rear springs are two elastomer bump
stops per wheel end.
1-18
TM 9-2355-320-10
Tires
Run Flat
This section describes the wheels, tires, and run flats. The illustration shows a typical section through the
assembly.
The tires are Michelin 16.00 R20 XZL Load Rated M. Table below shows the maximum load per tire, tire
pressure, and maximum speed for various conditions.
Tire Specifications
Tire Loading
Max Tire Load (lbs/kg) Max Speed (mph/kmh) Tire Pressure (psi/kPa)
12,500/5670 55/88 93/641
13,000/5897 55/88 97/669
13,333/6048 55/88 100/690
Maximum Speed for Conditions
Condition Max Speed (mph/kmh)
Paved Road Use 55/88
Secondary Road Use 35/56
Trail/Sand/Mud Use 20/32
Cross-Country Use 5/8
1-19
TM 9-2355-320-10
Fuel System
The vehicle is equipped with three fuel tanks. The Day Tank is located in the engine compartment. The
remaining two tanks are located externally, on the V section of the crew capsule, behind the driver’s door (left
side) and behind the passenger door (right side).
The fuel system has three manual shutoff valves which assist in maintenance or if damage to fuel tanks have
occurred. Right and left side tanks are connected with a cross-over tube. The cross-over tube has manual shut-
off valves on both ends. The third shut-off valve handle is located under the dash on the passenger side.
Rotating this handle will close the engine portion of the fuel system off from the rear tanks and only circulate fuel
from the Day Tank. The Day Tank provides a “limp home” capability.
The vehicle is re-fueled only on the left side and has an extended fuel filler neck due to the addition of Effector
panels and brackets.
The vehicle has a total of 79.9 gal. (302 l) capacity.
DAY TANK 3.9 GAL. (14.7 L)

LEFT SIDE TANK 46 GAL. (174 L)
RIGHT SIDE TANK 30 GAL. (113.5 L)
Fuel Supply
Line Shut off
Valve
RIGHT Manual
Return MAIN Fuel Shut off
Line Tank Valve
Day Tank Overflow

Return Fuel
Engine Line Line to left Cross-over
main fuel
tube
tank Personnel
Return Fuel Line
heater fuel
Manual shut off
line
valve (Under
dash)
Day Manual
Tank Shut off
LEFT
Valve
MAIN
Fuel Tank
Check Fuel Supply Shut off

Valve Line Valve
Wheels (Rims)
The wheel is a steel 10x20 in. (25x51 cm) design, two-piece bolted assembly capable of accepting the run-flat.
The wheel assembly is mounted to the reduction hub with ten studs, equi-spaced on a 335 mm PCD.
Run Flats
The MRAP RG33L Plus is fitted with Hutchinson VF-0223-C runflats, suitable for use with 16.00 R20 tires. The
VFI runflat prevents the separation of the tire from the rim, and the airtight seal against the rim prevents foreign
matter such as sand and mud entering the tire regardless of pressure, thus eliminating the use of beadlocks.
Brake System
This section describes the MRAP RG33L Plus brake system. The vehicle utilizes an air brake system and is fitted
with anti-lock sensors.
1-20
TM 9-2355-320-10
Service Brake
The vehicle is fitted with drum brakes on each wheel. The service brakes are air applied and spring released.
The service brakes are applied by depressing the operator’s brake pedal.
Air Dryer
A Bendix model AD-IS air dryer is fitted in the engine compartment. It is located after the air compressor and
feeds air to the reservoirs. The air dryer incorporates a safety valve to protect against excessive air pressure
buildup. The maximum allowable service system air pressure is 150 psi (1034 kPa). This dryer is equipped with
a 24 V, 100 W automatic heating element for moisture removal.
Reservoirs (Supply Tank, Secondary Service Tank, Primary Service Tank)

Three reservoirs for the air brake system serve as storage tanks for compressed air. The steel fabricated tanks
are as follows:
Function Size (gal./l)
Supply Tank 5/20
Primary Tank 9/33
Secondary Tank 9/33
1-21
TM 9-2355-320-10
Manual Drain Valve
Drain valves are installed in the air brake reservoirs to allow liquid contaminants collected to be drained off.
Low Pressure Switch

Bendix LP-3 Low pressure switches are attached in each reservoir. These pressure-operated electro-pneumatic
switches are designed to complete an electrical circuit and actuate a warning light and buzzer for the driver in the
event air pressure in the service brake system is below a minimum level for normal operation. This switch
activates at 60 psi (414 kPa).
Pressure Control Check Valve
The Bendix pressure control check valve is a normally-closed pressure sensitive control valve. The valve is used
to delay the filling of the secondary reservoir until a preset pressure is achieved in the primary reservoir.
Dual Foot Control Valve
The dual foot control valve consists of a moving two-part plunger, within the brake valve, that closes the valve’s
exhaust and opens passages within the valve that allow waiting air pressure to pass through and be delivered to
the rear and front brake systems.
Quick Release Valve
A quick release valve speeds up the exhaust of air from the brake chamber.
Relay Valve
Relay valves are primarily used on vehicles to apply and release rear axle(s) service or parking brakes. The
primary benefit of using a relay valve is the high capacity of air needed for braking is delivered directly and does
not have to travel up to the brake valve and then all the way to the brakes. The brake force is adjustable and
exhausts to the atmosphere when relieving pressure. Relay valves are typically mounted close to the brake
chambers they serve.
Stoplight Switch
Stoplight switches are pressure-sensitive elector-pneumatic switches installed in the service application system.
These switches operate the vehicle stop lights each time a brake application is made.
1-22
TM 9-2355-320-10
Parking/Emergency and Trailer Valves
The parking/emergency (2) and trailer (1) valves are mounted on the dash board. These valves are pressure
sensitive and will automatically change to the exhaust position if there is inadequate air pressure.
Quick Release with Two-Way Check Valve
This dual function valve works as a quick release valve for rapid park brake actuation and also provides anti-
compounding, since its double check valve prevents simultaneous service and emergency spring brake
applications. The anti-compounding feature occurs if the service brakes are applied while the spring brakes are
already applied. If this occurs, the valve will deliver air to the spring brake chambers to release the spring brakes.
Inversion Relay Valve with Anti-Compounding
Inversion relay valves are air-operated control valves and are normally open; i.e., without control pressure, the
supply is common to the delivery. The inversion valve is closed by using air pressure from another source and is
primarily used in emergency or parking brake systems. This valve also has a double check valve built into it to
provide anti-compounding. The latest inversion valve will provide air from the secondary supply tank to the
primary supply tank, if for some reason the primary supply line loses pressure.
Gladhands
Gladhands are mounted in both the front and rear of the MRAP RG33L Plus vehicle and provide air supplies for
the towed vehicle or for towing.
Antilock Braking System (ABS)
A Bendix ABS-6 system is fitted to the MRAP RG33L Plus vehicle per Bendix service data 13-4863. The ABS is
an electronic system that prevents wheel lock-up during braking to maintain the steering and stability of the
vehicle and to minimize the stopping distances under most circumstances. The ABS intervenes during braking
whenever the available friction between the road and the tire of the monitored wheel is less than the braking force
applied to the wheel, causing the wheel to decelerate (impending wheel to lock) quickly. The system consists of:
Speed Sensors
Bendix WS-24 wheel speed sensors are used and are located at each wheel to sense the instantaneous
movement of the wheels and to send an electronic signal directly proportional to the rotational velocity of the
sensed wheel to the electronic control unit.
1-23
TM 9-2355-320-10
Electronic Control Unit (ECU)
A Bendix EC-60 Preimum ECU is used to monitor the speed sensor signals and determines when the ABS
intervention is required and actuates the appropriate pressure modulation valves to optimize the brake pressure.
The ECU continually monitors the system to detect and warn the driver of any malfunctions. The ECU requires
24 V on a 30-amp fuse circuit directly to battery.
Pressure Modulation Valves
There are six Pressure Modulation Valves. Four are located in the ‘V’ of the hull and one in each fender well.
They are controlled electrically by the ECU to decrease, hold, or allow the full applied brake pressure into the
brake chamber to control the braking torque at the wheels.
Electrical System
The electrical system is a 24 volt system.
Batteries
The vehicle will incorporate four lead-acid HAWKER ArmSafe 12 V batteries. These batteries are accessible via
maintenance doors and are mounted on a slide-out tray on both sides of the vehicle.
Inverter
The vehicle is equipped with an OutBack true sinewave inverter located behind the commander’s seat.
Vehicle Power Distribution Box
The Vehicle Distribution Box (VDB) receives 4 sources of high power 24 VDC power lines (Alternator, Starter
Batteries, Vehicle Batteries, and NATO Slave Port) and distributes these power sources to the various Vehicle
Electrical and Government Furnished Equipment (GFE) mission equipment loads. The VDB will not allow reverse
current loads to connect to the master power bus, thus eliminating problems caused by reverse voltage conditions
during battery installation or miss-wired NATO slave plug or miss-wired Alternator power feeds. The VDB, also
referred to as the Power Distribution Center (PDC) box, is no longer a separate component located on the vehicle
floor between the driver and commander. The VDB has been incorporated into the dash and the controls are now
located on the auxiliary panel with the T-Case controls.
1-24
TM 9-2355-320-10
Vehicle Power Distribution Box – Continued
NATO Select
Battery Swap
Bus Connect
VDB Controls
Air Conditioning System

The air conditioning system consists of two engine-driven and mounted Sanden 4051/4052 compressors rated at
215 cc with R-134a refrigerant. These compressors feed dual condensers mounted on each front fender of the
chassis. Two evaporators are located in the vehicle. One evaporator is located behind the commander's seat
and provides cool air to the front crew and front right portion of the squad area. The second evaporator is located
in the left rear of the vehicle. The capacity of each loop is 33,000 BTU/hr (9.7 kW) providing a total system
cooling capacity of 66,000 BTU/hr (19.4 kW). The A/C cools air brought in through the ventilation from the rear of
the vehicle. The A/C also cools re-circulating air from the front and rear of the vehicle as it is pulled through the
evaporator coils.
Condenser
Evaporator
Evaporator
1-25
TM 9-2355-320-10
Compressors
The system uses Sanden 4051-4052 Compressors which are belt driven off the engine. Each compressor is
rated at 215 cc with R-134a refrigerant. The compressors electromagnetic single plate dry clutches are engaged
or disengaged as the crew selects A/C ON/OFF from the A/C control switch located on the vehicle dash.
Condensers
The condensers, receivers, and cooling fans are located in the engine compartment within the fenders on each
side of the vehicle. The condenser is a heat exchanger consisting of a coiled copper tube and cooling fins. As
the highly pressurized refrigerant (vapor) flows into the condenser, it gives off heat. Three fans pull air through
side grilles and through the condenser removing heat from the system. The receiver is located between two of
the cooling fans. The receiver stores excess liquid refrigerant when load conditions are low and provides added
refrigerant as required by the expansion valve.
Evaporator
The evaporator is similar in construction to the condenser consisting of a heat exchanger and fans. Each
evaporator has four centrifugal fans which pull air through the evaporator coils. The fans have 3 speeds,
providing a maximum of approximately 600 CFM (17 CMM) air flow. As heat is removed from the air, the
evaporators also remove moisture from the air coming through their fins and turn it into water. The condensate is
removed and drained away from the evaporator.
Ventilation/Duct Distribution System
The Environment Control System (ECS) consists of the air conditioning system, a fuel-fired personnel heater, and
a fresh air intake system configured for non-NBC operations. These systems are interconnected by a duct work
system that allows incoming fresh air to be pre-conditioned through the evaporator in warm conditions prior to
distribution into the vehicle. Moisture in the air is removed by the evaporator. During cold weather, air is pre-
conditioned by combining air from the heater and fresh air from the Ventilation system prior to distribution into the
vehicle.
1-26
TM 9-2355-320-10
Ventilation and Duct System
During non-NBC conditions, a ventilation system is installed in the ventilation box. This system uses the same
cyclone pre-cleaner. A nominal 200 CFM (5.6 CMM) fan is provided in-line with the system to provide adequate
fresh air for the crew and squad. A flexible duct connects the fan to a ballistic collar which provides shotline
protection as the air enters the rear of the vehicle. Air is directed to the evaporator and pulled through the cooling
coils. The evaporator fans push the air through the ductwork system where it is distributed through adjustable
louvers to the squad. The front evaporator has a similar ductwork system that provides air to the two forward
crewmen.
1-27
TM 9-2355-320-10
Personnel Heater
The vehicle is equipped with an A20 Personnel Heater manufactured by Hunter Mfg Co. The A20 Heater is a
dual output heater with the heat level selectable between 60,000 BTU/hr and 30,000 BTU/hr. A high – low switch
on the control box controls the heat output. Combustion air is brought in from outside the vehicle and combustion
exhaust gases are ducted outside for complete isolation of the combustion and ventilating air. The heater is user-
friendly with self-diagnostics and remote fault signaling. Fuel is routed from the main fuel supply to the heater.
The fuel inlet into the hull is protected by a ballistic cover. Heater controls are located on the dash.
Heater Installation Left Rear Corner Heater Installation - Exterior View
Heater Fuel Line Routing
1-28
TM 9-2355-320-10
Defroster
The defroster is manufactured by Mobile Climate Control. The unit is similar to traditional automotive defrosters
and utilizes engine coolant and a liquid-to-air heat exchanger to provide hot air to the crew and windshield.
Outlets are incorporated as part of dash assembly. Four hot air outlets are provided to defrost the windshield.
Defroster controls are located on the dash.
Automatic Fire Suppression System
WARNING
FM 200 is a health hazard. Exposure to skin can cause freezing, and inhaling high
concentrations may cause respiratory effects such as shortness of breath and produce heart
rhythm irregularities.
WARNING
get all personnel out of vehicle as soon as possible.
The system installed is an Automatic Fire Suppression System (AFSS). The AFSS System is an Automatic
Single Shot for Engine and Crew Compartments with manual override. The AFSS detects and suppresses all
possible types of fires; i.e., small or large, slow or rapidly growing, limited in area or widely spreading, as well as
fuel explosion which are likely to occur during combat or training service. The AFSS detects and suppresses
hydrocarbon fire and explosion in the Crew compartment with hatches open or closed. Suppression time is less
than 250 milliseconds.
The AFSS detects and extinguishes fire in the engine compartment in less than 10 seconds.
The AFSS has BIT (Built In Test) capability to enable to perform detectors and system test upon request and start
up. The AFSS has growth capability to upgrade to an automatic double shot system for crew and engine
compartments. In order to change the system to double shot, it will require adding two extinguishing cylinders to
crew compartment and one extinguishing cylinder to engine compartment and to update the electrical harness to
accept these new components. No changes are needed in the control box. The following table describes the
components needed for the MRAP RG33L Plus vehicle.
1-29
TM 9-2355-320-10
Automatic Fire Suppression System – Continued
AFSS characteristics:
1. Continuously monitors the system power supply, the cylinders’ operational status, and the proper operation of
the detection sub-system.
2. AFSS contains 3 extinguishing cylinders. Engine compartment has 1 cylinder used to extinguish fires
detected in the engine compartment by the detection wires. The crew compartment has 2 cylinders used to
extinguish fire detected in the crew compartment by the optical sensors.
3. AFSS control box has a BIT (Built in Test) used for continuous monitoring and reporting of systems status.
4. AFSS has the capability of both manual and automatic discharge of the extinguishing cylinders.
5. AFSS allows for external manual discharge of the extinguishing cylinders for up to 120 seconds after power
has been removed from the AFSS system.
The general layout is shown below:
Following is the AFSS Control Box located on dash.
AFSS Control Box
1-30
TM 9-2355-320-10
Driver’s Gauge Cluster
NOTE
Gauge cluster is not active until engine ignition and MASTER power switch is on.
Speedometer (1): Indicates speed of vehicle, with a range of 0 to 85 mph (0 to 140 kph).
Odometer (1a): Registers accumulated distance vehicle has traveled in miles.
Hour meter (1a): Registers accumulated hours the engine has operated.
Tachometer (2): Indicates speed of the engine, with a range of 0 to 3000 RPM.
Left (4) and Right (3) Fuel Gauges: Indicates amount of vehicle fuel remaining in the left and right fuel tank. A
yellow LED will illuminate when fuel is at 12% remaining in both tanks.
Engine Oil Pressure Gauge (5): Indicates engine oil pressure when the engine is running. Normal operating
range is 5.0 to 87.0 psi (35 to 600 kPa). Auditable tone will sound when engine oil pressure is outside normal
operating range.
Engine Coolant Temperature Gauge (6): Indicates engine operating temperature. Normal engine operating
temperature range is 104°F to 235°F (40°C to 113°C). Auditable tone will sound when engine coolant
temperature is higher than safe operating range.
NOTE
Normal engine operating temperature may not be reached on short trips. This is a normal
function parameter.
Air Pressure Gauges (7 and 8): Primary brake air pressure gauge (7) and secondary brake air pressure gauge (8)
indicate air pressure in pneumatic system at all times. Normal operating pressure range is 100 to 120 psi.
Auditable tone will sound when air pressure drops below safe operating range.
1-31
TM 9-2355-320-10
Driver’s Gauge Cluster – Continued
Transmission Temperature Gauge (9): Indicates the temperature of the transmission. Normal operating range
should be between 160°F and 200°F (71°C and 93°C).
Voltmeter Gauge (10): The voltmeter gauge indicate output voltage of the alternator when engine is running and
shows state-of-charge of batteries when engine is shut-down and the MASTER switch is set to on the position.
Normal operating range is 23 VDC to 28 VDC.
Annunciator Panel
NOTE
Annunciator Panel indicates the vehicle’s condition and hazards detected by devices within the
vehicle. Signals from the transducer and sources in the warning circuits are processed through
the annunciator panel and warnings are indicated if a problem exists in a specified system.
Warnings are conveyed in the form of illuminated Light Emitting Diodes (LEDs) and audible
alarms. In the event that the annunciator panel detects a problem, the applicable LED on the
annunciator panel will illuminate, and an audible alarm will be generated. The annunciator
panel is powered-up when the MASTER switch is set to the ON position.
Annunciator panel will not display faults or sound alarms until after initial start-up.
1. Annunciator panel uses 4 colors to display information.
a. Red Lamps indicate Warnings and require immediate actions by the operator. This warning will
also be accompanied by an audible signal.
b. Yellow Lamps indicate Cautions and require the operator to take action as soon as possible.
c. Green Lamps are for informational use by the operator in the operation of the vehicle.
d. Blue Lamp is used to indicate that the vehicle High Beams are in use.
2. The following indicators are located on the annunciator panel in order from top left:
1 2 3 4 5 6 7 8
16
12 13 15
9 10 11 14
Left Turn Indicator (1) – Indicates that the vehicle left turn signal is on. It uses a Green LED.
1-32
TM 9-2355-320-10
Annunciator Panel – Continued
Park Brake Indicator (2) – Indicates that the vehicle parking brake is engaged. It uses a Red LED.
Cruise Control Indicator (3) – Indicates that the cruise control is active. It uses a Green LED.
High Beam Indicator (4) – Will illuminate when the vehicle high beams are in use. It uses a Blue LED.
Rear Trailer Range Inhibit Indicator (5) – Indicates gear selection is being prevented. It uses a Yellow LED.
Front Anti-lock Braking System Indicator (6) – Indicates that a fault has been detected in the anti-lock brake
system. It uses a Yellow LED.
Low Fuel Indicator (7) – Indicates low fuel at 12% remaining for both right and left tanks. It uses a Yellow LED.
Right Turn Indicator (8) – Indicates that the vehicle right turn signal is on. It uses a Green LED.
Check Transmission Indicator (9) – Indicates that a fault has been detected for the transmission. It uses a Red
LED. Notify field maintenance when this indicator illuminates.
Transmission Over Temperature Indicator (10) – Indicates excessive transmission oil temperature. It uses a Red
LED. Notify field maintenance when this indicator illuminates.
Air Pressure (11) - Indicates low air pressure. It uses a Red LED and is accompanied by an audible alarm.
Auxiliary Brake Indicator (12) – Indicates secondary braking device is active. It uses a Green LED.
Water in Fuel Indicator (13) – Indicates presence of water in fuel filter. It uses a Yellow LED. Notify field
maintenance when this indicator illuminates.
Wait to Start Indicator (14) – Indicates active engine air preheat cycle. It uses a Yellow LED.
Check Engine Indicator (15) – Indicates that a non-critical engine fault has been detected. It uses a Yellow LED.
Notify field maintenance when this indicator illuminates.
Stop Engine Indicator (16) – Indicates that a critical engine fault has been detected. It uses a Red LED. Notify
field maintenance when this indicator illuminates.
3. Audible alarms will sound for the following reasons:

a. Stop Engine Indicator is illuminated.
b. Engine water temperature is higher than safe operating range.
c. A problem with the transmission has been detected because of fault or temperature.
d. Engine oil pressure is outside normal operating range.
e. Air pressure in the braking system has dropped below safe operating range.
f. Check Engine Indicator has illuminated.
1-33
TM 9-2355-320-10
Annunciator Panel – Continued
ANNUNCIATOR
START/POWER PANEL
SWITCHES DVR’S GAUGES &
WARNING LIGHTS
TRANSMISSION
SHIFT SELECTOR AFS
GO LIGHT
CONTROL
WINDSHIELD
EXTERIOR WIPER
LIGHTS CONTROLS
BLACKOUT AIR
LIGHTS RESTRICTION
CONTROL GAUGE TRAILER
AIR SUPPLY
DEFROSTER A/C CONTROLS
HEATER
PARKING CONTRO
BRAKE
Rear and Side Door Assist

The vehicle is equipped with side and rear door assist mechanisms to aid the soldier in opening and closing the
door. This reduces ingress and egress times and allows the user to open and close the door when the vehicle is
on sloped terrain.
Side Door Assist
The side door assist system is used to open and close the driver and commander doors on the vehicles. Due to
increased armor on the side doors, each door now weighs approximately 1400 lb (636 kg) and requires powered
assistance to open and close. The side door assist mechanism uses a hood-mounted electro-hydraulic actuator
to rotate the door through a complete 90 degrees at vehicle orientations of up to 30% grade and 30% side slope.
On level surface the assist mechanism will open or close the door in approximately 6 seconds.
The assist mechanism uses a programmable IQAN-MC2 for controlling the electro-hydraulic system. The door is
equipped with sensors to determine the following door states: door closed, door latch engaged, blast lock
engaged, and door fully open. A toggle switch on the interior dash and exterior front fender allow the soldier to
easily open and close the door from a safe position. When the door is closed, the blast lock and door latch must
first be disengaged by the soldier before the actuator will be operable.
The door assist mechanism also contains a door-mounted safety sensor to prevent accidental crushing, and an
interior/exterior manual release in case of actuator failure. The safety sensor is a pressure sensitive device that
will automatically stop and reverse the door when activated. The manual release pull cable provides a backup
measure for releasing the force on the activator and allows the cylinder to extend and retract with a greatly
reduced force.
1-34
TM 9-2355-320-10
Rear Door Assist
An internally-mounted pneumatic actuator is used to open and close the rear door. It is the same basic design as
the SOCOM MRAP variant and opens or closes the rear door in approximately 5 seconds. The system requires
80-90 psi (552-621 kPa) of air pressure to operate and is supplied by the vehicles existing pneumatic system.
Three separate toggle switches are mounted on the vehicle for opening and closing the doors. Two are located in
the rear, both externally and internally, and one is dash mounted for use by the driver or commander. An
emergency open/close valve is located internally at the rear of the vehicle that allows the user to open or close
the door without vehicle power.
1-35
TM 9-2355-320-10
Armor
The MRAP RG33L Plus contains survivability enhancements over previous MRAP variants that improve small
arms fire, mine blast, IED and EFP protection. The MRAP RG33L Plus contains appliqué armor mounted to the
upper V and vertical sides, and adjustable Effector Packs mounted to the side of the vehicle. In addition, the
MRAP RG33L Plus uses thicker ballistic windows and is raised 3.9 inches to improve blast resistance.
Applique Armor Effector Panels
1-36
TM 9-2355-320-10
CHAPTER 2 – OPERATOR INSTRUCTIONS
OPERATE PARKING BRAKE/TRAILER AIR SUPPLY CONTROL
WARNING
Do not rely on the parking brake on steep slopes. Parking brake will not hold vehicle on slopes
greater than 20 percent (11°). Always use wheel chocks in conjunction with vehicle parking
brake. Failure to comply may result in severe injury or death to personnel and/or damage to
equipment.
CAUTION
If the pneumatic system pressure is lost, parking brake valve will exhaust at 30 psi (206.8 kPa).
If air pressure warning alarm sounds, stop vehicle as soon as possible. Failure to comply may
result in damage to equipment.
NOTE
Parking brake will not release until pneumatic system air pressure reaches 60 psi (413.7 kPa).
1. Operate parking brake control valve (Yellow):

a. Push in parking brake control (2).
b. Verify LED (3) on annunciator panel extinguishes; this indicates release of the parking brake.
3
c. Pull out parking brake control (2).

d. Verify LED on annunciator panel illuminates; this indicates activation of the parking brake.
2. Operate trailer air supply valve (Red):
NOTE
Do not use trailer brake for parking.
a. Push in trailer air supply control valve (1) to activate trailer air system.
b. Pull the trailer air supply control valve (1) to remove air supply from the trailer air system.
2-1
TM 9-2355-320-10
CHAPTER 2 – OPERATOR INSTRUCTIONS - CONTINUED
MASTER POWER AND OFF/RUN/START SWITCHES
CAUTION
To avoid damage to starter, never move ignition switch to ‘START’ if engine is running.
Additionally, never operate starter for longer than 30 seconds at a time. Allow 2 minutes
between starting attempts to allow starter to cool down. Failure to comply may result in
equipment damage.
All electrical switches, except the OFF/RUN/START and Master Power switch, must be set to
OFF positions before engine is shut down.
1. The Master Power switch (1) is a two-position ON/OFF switch. When the Master Power switch is in the OFF
position, main battery power is disconnected from the OFF/RUN/START switch and most vehicle systems.
Systems such as the side door assist and personnel heater are still operational.
2. The OFF/RUN/START switch (1) is a three-position switch.
a. Down position is the OFF position. No power is applied to the engine.
b. Center position is the RUN position. Power is applied to the engine to allow for engine operation. The
center position also applies power to the engine pre-heater during start up.
c. Up position is the engine START position. Power is applied to the engine starter and allows for vehicle
start up.
2-2
TM 9-2355-320-10
ENGINE START PROCEDURE
CAUTION
Do not increase engine speed until oil pressure gauge indicates normal condition. Oil pressure
should rise within 15 seconds after engine starts. If oil pressure is not indicated on gauge
within 15 seconds, cease vehicle operation and notify Field Maintenance. Failure to comply
may result in damage to equipment.
NOTE
At initial engine start-up, allow engine to idle at least 30 seconds to ensure sufficient oil
circulation to turbocharger bearings.
If check engine indicator illuminates on the annunciator module after starting, notify Field
Maintenance.
1. Ensure parking brake (4) has been applied (pulled out).

2. Ensure gear range selector (3) is in the Neutral (N) position.
3. Ensure communications and electrical equipment switches are in OFF position.
4. Put Master Power switch (1) in the ON position.
CAUTION
To avoid damage to starter, never engage start/power switch if engine is running.
Never operate start/power switch in the start position for more than 30 seconds at a time. Allow
2 minutes between start attempts to allow starter to cool down. Failure to comply may result in
equipment damage.
5. Set engine start/power switch (2) to the RUN position.
6. Wait until yellow WAIT light extinguishes on annunciator panel before attempting to start the engine.
NOTE
Alert personnel to vehicle starting. Do not start vehicle engine until yellow ‘Wait’ light
extinguishes and ensure all gauges and warning indicators have stabilized, and all modules
have completed startup BIT/BITE sequences prior to attempting to start engine. If engine
preheat icon does not extinguish after two minutes, notify Field Maintenance.
Do not depress accelerator while cranking engine.
7. Move OFF/RUN/START (2) switch to START position and release when engine starts. Switch will
automatically return to RUN position. Make sure no warning indicators remain illuminated before beginning
operation.
2-3
TM 9-2355-320-10
TRANSMISSION SHIFT SELECTION
WARNING
Control failures can cause vehicle to crash. A crash can cause severe injury or death to
personnel. Check all controls for smooth operation. Do not drive vehicle if accelerator,
steering, or brake controls bind, or fail to return when released. Do not operate vehicle if
engine does not return to idle when accelerator pedal is released.
To avoid injury or property damage caused by sudden movement of the vehicle, do not make
shifts from N (Neutral) to D (Drive) or (R) Reverse while the accelerator pedal is depressed.
Vehicle may impact objects, personnel, or other vehicles while backing. Use ground guides.
If you leave the vehicle while the engine is running, the vehicle can move unexpectedly and you
or others could be injured. If you must leave the engine running, do not leave the vehicle until
you have completed all of the following procedures:
1. Put the transmission in N (Neutral).

2. Be sure the engine is at low idle (500-800 RPM).
3. Apply the parking brake and emergency brake and make sure they are properly engaged.
4. Chock the wheels and take any other steps necessary to keep the vehicle from moving.
CAUTION
Do not idle in D (Drive) for more than 5 minutes. Extended idling in D (Drive) can cause
transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds
5 minutes.
Do not idle in R (Reverse) for more than 5 minutes. Extended idling in R (Reverse) can cause
transmission overheating and damage. Always select N (Neutral) whenever time at idle exceeds
5 minutes.
NOTE
Visually check the range select digital display window whenever a range select button is
pushed to be sure the range selected is shown. A flashing display indicates a range is either
temporarily or permanently inhibited. The range inhibit should clear within 3 seconds of the
shift request.
Completely stop the vehicle and let the engine return to idle before shifting from D (Drive) to R
(Reverse), or from R (Reverse) to a forward range in D (Drive).
2-4
TM 9-2355-320-10
TRANSMISSION SHIFT SELECTION – CONTINUED
8. The transmission shift selector (1) is a pushbutton type selector mounted to the dash. The shift selector has a
digital display (2), a MODE button (3), range selection buttons (4), and up/down range arrow indicators (5).
WARNING
Do not press up/down range arrow indicators while operating vehicle under usual
conditions, as changing the functioning of the automatic transmission will reduce
braking and could cause loss of control, including loss of vehicle due to a crash. A
crash can cause severe injury or death to personnel.
9. When the D range selection button is pressed, the first number in the digital display (2) indicates the highest
forward range available; the second number indicates the current range attained. The transmission will start
out in the lowest available forward range, and as the vehicle speed increases, the transmission will upshift
automatically through each range. As the vehicle slows down, the transmission will automatically downshift to
the correct range. It is not necessary to select the right moment to upshift or downshift during changing road
and traffic conditions. The transmission does it for you.
10. When the N or R range selection button is pressed, the digital display (2) will indicate N or R accordingly.
11. Visually check the digital display (2) whenever a button is pushed to be sure the selected range is shown. A
flashing display at the digital display (2) indicates the range selected was not attained due to an active range
inhibit. Wait 3 seconds and press the desired range once again. If the flashing display does not clear after 12
seconds, report this condition to Field Maintenance.
12. As your vehicle begins its motion, ensure that the transmission shifts in all ranges. If the check transmission
icon (6) or transmission fluid overtemp icon (7) on annunciator panel illuminates, check the digital display (2)
for a possible transmission fault. Notify Field Maintenance for diagnostics check and repair.
4
3
2-5
TM 9-2355-320-10
DRIVE VEHICLE
WARNING
Close all hatches, doors, and secure all equipment before moving out. Personnel standing in
hatch may be ejected and killed during sudden vehicle movement. All personnel must remain
seated with seat restraints fastened during vehicle operation. Failure to comply may result in
injury or death to personnel from shifting equipment, or damage to equipment may occur.
1. Release parking brake.

NOTE
Parking brake will not release until air pressure reaches 60 psi.
a. Press operator brake pedal to steady vehicle.

b. Push in parking brake control to release the parking brake.
c. Verify LED on annunciator panel extinguishes; this indicates release of the parking brake.
2. Set transfer gearbox mode.
To drive in the 4 x 6 normal operating mode, verify no switches selected on terrain mode selection panel.
3. Set transmission gear.
NOTE
Transmission will start out in the lowest available forward range, and as the vehicle speed
increases, the transmission will upshift automatically through each range.
Press gear range selector to D (Drive) (2) or Reverse (R) (1) position and prepare to drive the vehicle in
selected direction.
NOTE
Monitor gauges and displays to observe vehicle operating status.
4. Steer vehicle in forward range.
a. Hold steering wheel and prepare to drive the vehicle forward.
b. Release operator brake pedal and press accelerator pedal to drive forward.
c. Steer vehicle in desired direction using steering wheel.
2-6
TM 9-2355-320-10
DRIVE VEHICLE - CONTINUED
5. Steer vehicle in reverse range (R).
WARNING
Post ground guides to the side of vehicle at front and rear before backing up. Failure to comply
may result in injury or death to personnel.
a. Bring vehicle to complete stop.
b. With foot on the brake pedal, press gear range selector to R (Reverse) position to prepare for driving in
reverse.
CAUTION
Small changes in steering wheel movement cause large changes in the way the vehicle reacts
to your input. Always drive slowly and with great care while driving in reverse. Failure to
comply may result in severe injury or death to personnel.
c. Using the mirrors located outside your vehicle, turn the steering wheel slightly in the direction you are
backing, while gently depressing the accelerator pedal.
d. Continue making a series of small turns, using the steering wheel, until vehicle is pointing in desired
direction.
6. Bring vehicle to a stop.
WARNING
Air brakes are very sensitive in operation. Braking force is proportional to the distance the
brake pedal travels, but the driver does not experience the resistance from the brake pedal.
NOTE
MRAP RG33L Plus service brakes are air operated. Braking action is achieved by pressing the
brake pedal. Air disc brakes convert air pressure into braking force. The braking action is
similar to automobile braking; however, the driver cannot feel braking force through feedback in
the brake pedal pressure.
As the vehicle slows down, the transmission will automatically downshift to the correct range.
a. Press the brake pedal so you can steer and control the vehicle to stay in a straight line.
b. Bring the vehicle to a stop.
c. Press the N (Neutral) range selection button on the transmission shift selector and the display will
indicate ‘N’.
d. Engage the parking brake by pulling on the knob.
e. Verify parking brake indicator (1) illuminates on annunciator panel.
2-7
TM 9-2355-320-10
STOP ENGINE
CAUTION
Master Power switch should never be turned off when engine is running. Electrical and
electronic equipment could be damaged.
NOTE
If engine is operated at a low speed, allow engine to idle for 30 seconds before shutdown. If
engine is operated at high speed with heavy load condition, allow engine to idle for 3 minutes
before shutdown.
1. Apply service brake to stop vehicle (if required).

2. Place transmission shift selector (3) to Neutral (N).
3. Engage parking brake (4) and verify that parking brake (P) indicator illuminates on annunciator panel.
4. Move communications and electrical equipment switches to OFF positions.
5. Move OFF/RUN/START switch (2) to OFF position.
CAUTION
Allow 30 seconds after turning engine start switch to OFF before turning Master Power switch
OFF.
6. Move Master Power switch (1) to OFF position.

3
2-8
TM 9-2355-320-10
STEERING COLUMN CONTROLS
NOTE
Ensure Master Power switch is ON.
1. Press horn (2) at center of steering wheel to ensure it sounds.
2. Operate High/Low Beam.
a. Turn on headlights.
b. Toggle signal arm (1) rearward (towards driver) to put high beam on.
c. Check annunciator panel to ensure high beam indicator icon is illuminated.
d. Toggle signal arm (1) forward to select low beam.
e. Check annunciator panel to ensure that high beam indicator icon extinguished.
3. Operate Turn Signal Arm.
a. Toggle signal arm (1) down for left turn signal.
b. Check gauge cluster to ensure that the signal is indicated.
c. Toggle signal arm (1) up for right turn.
d. Check gauge cluster to ensure that signal is indicated.
4. Operate Four-Way Flashers.
a. Press red switch (4) located underneath toggle signal arm.
b. Ensure that gauge cluster signals flash together.
c. Press red switch (4) to cancel four-way flashers.
5. Operate telescoping tilting controls (3) of steering column:
NOTE
The steering column has a seven-position tilt and is a 2.25” telescopic type with a 16” steering
wheel.
a. Telescoping of steering column is accomplished by pushing steering column lever (3) back.
b. Tilting of steering column is accomplished by pulling steering column lever (3) forward.
c. Center position of steering lever (3) will lock steering column in place.
2-9
TM 9-2355-320-10
OPERATE HATCHES
WARNING
death to personnel.
NOTE
Opening the crew hatch cover is a dual-action process, best performed with both hands.
Open
1. Place right hand on hatch handle (1).
2. Pull down hatch release strap (2) with left hand.
3. As hatch release disengages, push door open with right hand.
4. Swing hatch cover out/open 90° until locking pin (3) engages, securing hatch in open position.
2-10
TM 9-2355-320-10
OPERATE HATCHES - CONTINUED
WARNING
death to personnel.
Close
1. Hold hatch handle (1) with left hand.
2. Reach outside and pull engaged locking pin (3) out with right hand.
3. As hatch lock disengages, pull door in with left hand. Release hatch lock after pulling hatch out of fully
opened postion.
4. Swing hatch cover to closed position and hatch handle (1) until latch engages to secure hatch cover closed.
2-11
TM 9-2355-320-10
OPERATE TURRET HATCH COVER
OPEN
1. Unlatch three inside latches (1) securing hatch assembly.
2. Fold front half hatch assembly back until it latches onto main hatch.
3. Push folded hatch assembly until it locks against rear armor.
WARNING
death to personnel.
CLOSE
1. Push back on hatch (2) and lever (3) to release hatch assembly.
2. Unfold front half hatch assembly inward from main hatch and pull hatch shut.
3. Secure hatch by closing three inside latches (1).
2-12
TM 9-2355-320-10
OPERATE SIDE DOOR ASSIST
WARNING
Remove all objects from the vicinity of the side doors when opening the doors with the door
assist system. Keep hands and arms away from the doors when closing to avoid injury to
personnel or damage to equipment.
Effector armor is a pinch point. Keep hands and arms away from armor. Failure to comply with
this warning could result in damage to equipment and serious injury or death to personnel.
clear of doors before closing. Failure to comply with this warning could result in damage to
equipment and serious injury or death to personnel.
NOTE
Door assist cannot be operated from outside with combat lock engaged.
From outside the vehicle:

1. The side door assist system operation from outside the vehicle is accomplished by toggling the electric
switches (1) mounted on the driver and passenger side of the fender.
2. The doors can also be opened by pulling the manual release cable handle (2) mounted externally on the
driver and passenger side. Rotate manual release cable 1/4 turn clockwise to keep cable in released
position.
1
2
2-13
TM 9-2355-320-10
OPERATE SIDE DOOR ASSIST - CONTINUED
3. The door can also be opened by forcefully pulling the handle (1) underneath the door to activate door assist.
NOTE
Side door assist will not open if either or both release cable handles are pulled.
Side door assist system will not work unless the doors are unlocked.
From inside the vehicle:
1. The side door assist system can be activated from inside the vehicle by toggling the right or left door assist
switches on the switch panel (1).
2. The doors can also be opened by pulling the manual release cable handle (1) mounted under the dashboard
on the driver and passenger side. Rotate manual release cable ¼ turn clockwise to keep cable in released
position.
2-14
TM 9-2355-320-10
OPERATE REAR DOOR
WARNING
Remove all objects from the vicinity of the rear door when operating the door. Keep personnel,
hands, and arms away from the door when closing or opening. Failure to comply may result in
serious injury or death.
clear of doors before closing. Failure to comply with this warning may result in serious injury
or death to personnel and/or equipment.
From outside the vehicle:

1. The rear door is opened by toggling the exterior switch (1) to the “open” position and holding it until the door is
fully open. To close door, hold switch in the “close” position until door closes. The switch is located
underneath the rear stowage box to the left of the door.
2-15
TM 9-2355-320-10
OPERATE REAR DOOR - CONTINUED
From inside the vehicle:
1. The rear door is opened by toggling the interior switch (2) to the “open” position and holding it until the door is
fully open. To close door, hold switch in the “close” position until door closes. The switch is located directly
above the rear door.
WARNING
Only use auxiliary panel rear door switch in emergency situations. Failure to comply may result
in serious injury or death to personnel.
2. The rear door can also be opened by using the “rear door” switch (3) on the driver’s instrument panel at the
front of the vehicle. Press and hold the switch in the “up” position to open door. Press and hold the switch in
the “down” position to close door.
2-16
TM 9-2355-320-10
ADJUST SEAT TRAVEL
WARNING
1. Pull up horizontal control lever (1) and move seat to front or rear.
2. When positioned, release horizontal control lever (1) to lock seat in place.
ADJUST SEAT BACK
WARNING
1. Rotate seat back adjustment knob (2) to adjust seat back angle.
2 1
2-17
TM 9-2355-320-10
OPERATE ALL WHEEL DRIVE (AWD) AND TRANSFER CASE (T-CASE) SELECTOR SWITCHES
Engaged
Selection Light
NOTE
Rear differential lock switch engages both rear and intermediate differential.
1. To select All Wheel Drive (AWD) position:

a. Stop vehicle.
b. Shift transmission to neutral (N).
c. Toggle AWD switch (1) to up position. AWD selection light will illuminate.
d. Shift transmission into gear. “AWD ENGAGED” light will illuminate.
e. Continue with vehicle operation.
2. Disengage AWD:
a. Stop vehicle.
b. Shift transmission to neutral (N).
c. Toggle AWD switch in down position.
3. Operate Differential Lock:
NOTE
The differential lock locks the left and right tires on all axles together for severe off road
conditions and is only available in the AWD mode.
a. Bring the vehicle to a complete stop.
NOTE
• Both the rear and front differentials can be locked.

• Toggle switch will return to center position after selecting mode.
• Vehicle may need to move to engage or disengage differential lock.
• Front differential lock cannot be selected until rear and mid differentials have been
selected.
2-18
TM 9-2355-320-10
OPERATE ALL WHEEL DRIVE (AWD) AND TRANSFER CASE (T-CASE) SELECTOR SWITCHES -
CONTINUED
b. Toggle Differential Lock switches (2) to the up position to lock differentials. Selection light will illuminate.
When either or both differential locks are engaged, the “Front Diff Engaged” or “Rear Diff Engaged” lights
above “Front Diff Lock” or “Rear Diff Lock” indicator lights will be illuminated.
To unlock differentials, toggle switches (2) down. All indicator lights will go out. The front differential will
disengage automatically when the rear differential lock is disengaged. Both front and rear differential locks will
disengage automatically when AWD mode is disengaged. Move vehicle in reverse to disengage differential locks.
NOTE
When “Transfer Case Neutral” and “Transfer Case Low” are not selected, vehicle is in “High
Range”
4. Operate Transfer Case (T-CASE) LO Range Switch:
a. Place transmission in neutral (N). Selection light will illuminate.
b. Toggle T-CASE range switch (3) up, Low Range. Selection light will illuminate.
c. Place transmission in gear (D1 or R).
d. Operate vehicle.
5. Disengage Transfer Case (T-CASE) LO Range;
a. Stop vehicle completely.
b. Shift transmission to Neutral (N).
c. Toggle LO Range switch (3) down.
e. T-CASE LO engaged indicator will extinguish.
ENGAGED
4
ILLUMINATION
3
SELECTION LIGHT
6. Engage T-CASE Neutral:

a. Transmission must in be Neutral (N).
b. Toggle T-CASE LO SPEED range switch (3).
c. Toggle T-CASE NEUTRAL range switch (4) UP.
d. Place transmission in Drive (D) to engage T-CASE Neutral.
e. T-CASE will exit Neutral if LO SPEED is deselected.
f. T-CASE will not change out of Neutral or LO until transmission Neutral (N) is selected.
2-19
TM 9-2355-320-10
OPERATE LEFT AND RIGHT SCENE LIGHT SWITCHES
1. Toggle left (1) or right scene light switch (2) up for ON or down for OFF. Scene light indicator above toggle
switch will illuminate only when the switches are in the ON position.
OPERATE WINDSHIELD WIPER

1. Switch 1 – Wiper operation
a. Push top of switch (1) for high speed.
b. Middle position for low speed.
c. Push bottom of switch to turn wipers off.
2. Switch 2 – Washer pump operation
Push top of switch (2) to spray windshield wiper fluid.
2-20
TM 9-2355-320-10
OPERATE INTERIOR LIGHTS
NOTE
Power for interior lighting is controlled by the Master Power switch.

1. Cab Dome – Put the cab dome switch (1) in the UP position to turn cab dome lights on.
2. Crew Overide – Put the crew override switch (2) in the UP position to override the crew dome light selector
switch (3) position in the squad compartment.
3. Lighting intensity – Adjust lighting intensity with control knob (4).
4. Emergency lighting – Press the ‘EMER’ switch (5) on the dome light to select emergency (green) lighting.
CAB CREW
CREW
CREW CONTROLS
LIGHTS
DOME
LIGHTS
LIGHTS
2-21
TM 9-2355-320-10
OPERATE GOLIGHT
1. To operate roof mounted golight, push the golight switch (3) to the “ON” position. Indicator light (2) next to
switch (3) will illuminate to indicate golight is on. Use the rotational switch (1) to rotate the spotlight in the
desired direction.
2-22
TM 9-2355-320-10
HEATING SYSTEM OPERATION
The MRAP RG33L Plus is equipped with an automatic dual-output, electronic, multifuel-fired, 60,000 BTU/hr
vehicle personnel heater. The heater is user-friendly with self-diagnostics and remote fault signaling. The heater
operates from any 24 VDC power source, and produces heat through the combustion of diesel or jet grade fuels.
WARNING
Engine and personnel heater exhaust fumes are very toxic.
Do not run heater or engine indoors unless you have very good air flow.
If fumes are noticed inside of vehicle, immediately turn on vent fans and open all hatch covers
and the ramp access door.
Vehicle engine and personnel heater exhaust fumes contain carbon monoxide and other
materials that are toxic. Exposure to high levels can kill or severely injure personnel.
NBC mask will filter out smell of diesel and diesel exhaust. However, NBC mask will not filter
out carbon monoxide and other toxic materials.
To protect yourself and other personnel from exhaust and carbon monoxide poisoning, obey
the following rules:
• Do not run heater or engine indoors unless there is a good flow of fresh air.
• Do not operate vehicle or personnel heater if any powerpack access covers, plates, or
doors are open. If maintenance requires engine or heater operation with access covers,
plates, or doors open or removed, ensure there is a good flow of fresh air to remove
exhaust gases.
Remember: The best defense against exhaust gas poisoning is a good flow of fresh air.
Shut off the personnel heater if: fuel leakage or fuel pooling is observed; heater will not start in
specified time following proper procedures (heater lamp does not come on); blower does not
operate or heater goes out (heater lamp goes out). Failure to comply may result in personnel
injury or death and/or equipment damage due to potential for a crew compartment fire.
Should heater not start within three (3) consecutive attempts, refer to Chapter 3 and
troubleshoot heater system. DO NOT attempt to start a flooded heater or use starting aids such
as ether to assist in heater start up, or a fire hazard may occur resulting in possible injury or
death to personnel.
DO NOT place combustible materials within three (3) feet of heater exhaust. Failure to comply
may result in personnel injury or death and/or equipment damage due to fire.
DO NOT smoke or allow open flames nearby while conducting maintenance work on heater as
diesel fuel and its fumes can be explosive.
If heater has been running recently, the igniter, exhaust port, and heat exchanger are hot
enough to burn unprotected skin.
Carbon monoxide is a colorless, odorless gas, and if inhaled, can be lethal. Never operate a
heater indoors without venting exhaust outdoors. The heater consumes oxygen and produces
carbon monoxide gas that is vented through heater exhaust.
After disconnecting electrical power from the heater and detaching the MS Power Connector,
the Pins A and D of the heater’s male connector remain electrically live with 24 VDC. This
condition remains for approximately five (5) minutes while the capacitor discharges. Personnel
should avoid touching the contacts of this connector as electrical shock may occur.
Remove heater from vehicle prior to any welding on hull as transient current could damage
circuit boards.
Particles blown by compressed air are hazardous. When using compressed air to clean the
inside parts of the heater, do not exceed 30 psi (207 kPa) air pressure. Make certain that the
airstream is directed away from the user and other personnel in the immediate area. To prevent
injury, personnel must wear protective gloves and goggles or face shield when using
compressed air.
2-23
TM 9-2355-320-10
HEATING SYSTEM OPERATION - CONTINUED
CAUTION
If any smoke appears during any mode of heater operation, shut down heater and check for
airflow obstructions. It is possible frost has built up in the combustion air intake or that debris
has entered into the combustion system. Failure to comply may result in heater damage.
The personnel heater may not start or run above 75° F (23.88° C). Do not attempt to operate
heater if vehicle interior temperature is above 75° F. Heater will display a fault code if vehicle
interior temperature is above 104° F (40° C). The heater will automatically switch to LO if vehicle
interior temperature is above 113° F (45° C). Heater will not start or will shut down if vehicle
interior temperature is above 131° F (55° C). Heater will shut down if heater output temperature
is above 345° F (173.88° C).
NOTE
The heater can be operated with Master Power switch OFF. Operate in this mode for only short
periods of time. Vehicle battery reserve power will deplete rapidly in cold weather.
STARTING HEATER
1. Confirm the START/OFF/RUN switch (3) on heater control box (4) is in OFF position.
NOTE
The heater can be started with the HI/LO switch in HI or LO position.
Heater life will be extended if operated in LO temperature setting.

2. Set HI/LO switch (1) to desired position for heat control.
3. Move START/OFF/RUN switch (3) to START and hold for approximately four seconds or until indicator light
(2) comes on, then move the START/OFF/RUN switch (3) to RUN position. The heater will process various
modes and display run mode 06 (Table 1) on the heater diagnostics display during start-up. When heater is
in run mode, diagnostic LED display on heater will indicate 07 in low heat mode and 14 in high heat mode.
4. If the indicator light (2) fails to light within 3.5 minutes, move START/OFF/RUN (3) to OFF, and allow heater
to purge (this will take approximately four minutes). Attempt to start heater. If heater does not start, consult
troubleshooting procedures. If heater does not start after a total of three attempts, notify Field Maintenance.
Table 1. Operational Modes (displayed on personnel heater).

00 Shutdown Purge
01 Self Check
02 Ignitor On
03 Deliver Fuel
04 Ignitor Off
05 Full Heat Ramp
06 Enter Run Mode
07 Low Heat Mode
14 High Heat Mode
99 Vent Only
2-24
TM 9-2355-320-10
HEATER SHUTDOWN
NOTE
During shutdown and purge cycle, the heater will not respond to the control box switch until the
three minute purge cycle is completed.
When the personnel heater is OFF, the blower will run and the heater indicator light will remain
illuminated until the heater purge cycle is completed. Driver should remain in the vehicle until
heater shutdown is complete.
Move START/OFF/RUN switch (2) to OFF position on control box (3). After two seconds, the heater will enter
Purge Mode, and after three minutes the heater will automatically shut off.
HEATER OPERATION FAULTS

Warning Faults
During operation, if an abnormal condition occurs, an indicator light (1) on the control box (3) will begin flashing
and a run code (07 or 14) will be displayed on diagnostic display. The heater will try to correct the fault. If fault
cannot be corrected, heater will continue to operate until an unsafe condition or component failure FAULT occurs.
Then heater will automatically shut down and a failure code will be displayed on the diagnostic display (Table 2).
Table 2. WARNING Faults.

C7 Fuel Pressure Sensor Fault
C9 Fuel Pump Fault
E2 Low Fuel Pressure
E5 Inlet Over Pressure
E6 System Voltage
F3 Heat Limit
F6 Ambient Over Temperature
2-25
TM 9-2355-320-10
HEATER OPERATION FAULTS - CONTINUED
Shutdown Faults
If a shutdown fault occurs, the heater will immediately enter the shutdown and purge modes to avoid operating in
an unsafe condition. The diagnostic display will display the fault mode and the control box indicator light (1) will
flash in cycle composed of one flash followed by a two second display. Refer to Table 3 for Shutdown Faults and
notify Field Maintenance.
Table 3. Shutdown Faults.

C1 Igniter Fault
C2 Igniter Short
C3 Vent Fan Fault
C4 Burner Fan Fault
C5 Burner/Exhaust Sensor Fault
C6 Vent Sensor Fault
C8 Controller Fault
CA Fuel Injector Fault
E1 Low Voltage
E3 Low Burner Air Flow
E4 Reverse Burner Air Flow
E6 System Voltage
F1 Ignition Overtime
F2 Burner Flame Out
F4 Vent Air Over Heat
F5 Over Current
F7 Exhaust Over Temperature
F8 Ignition Flames Out
2-26
TM 9-2355-320-10
OPERATE AIR CONDITIONING AND VENTILATION SYSTEM
NOTE
• Engine should always be running when operating the air conditioning and ventilation controls.
• A/C unit fans will still operate when green compressor switch is OFF.
1. To operate the Air Conditioning (A/C) system, turn compressor switch (1) to the ON position. The green light
will illuminate to indicate A/C system is ON. Adjust the fan speed by setting the fan speed switch (2) to the
desired setting.
2
1
2. To operate the ventilation system, move the vent fan switch (1) into the ON position. The ventilation fan will
filter outside air into the vehicle cabin.
2-27
TM 9-2355-320-10
OPERATE DEFROSTER
NOTE
Engine should always be running when operating the defroster controls.
Turn defroster ON by moving fan control switch (2) to the 1, 2, or 3 position. Adjust defroster temperature by
moving temperature switch (1) to desired setting. Turn defroster OFF by moving fan control switch (2) back to 0.
2
1
2-28
TM 9-2355-320-10
AIR CLEANER
NOTE
If at any time you see only red in the window of the air cleaner restriction indicator, and the
yellow button does not reset when pushed, notify Field Maintenance.
1. Check air cleaner restriction indicator (1) located on driver’s dash. Verify that air filter restriction minder
gauge reading (2) is in the safe (green) operating zone.
2. Replace the air filter element (Chapter 5) or notify Field Maintenance if air filter restriction gauge tool shows
color red, and reads above 22 in. H20 (5.5 kPa).
3. Push the yellow button (3) at the bottom of the air filter restriction gauge, whenever the air filter is cleaned or
replaced, to reset the air filter restriction gauge.
2 3
2-29
TM 9-2355-320-10
ENGINE EXHAUST BRAKING CONTROL
WARNING
Do not rely on engine exhaust brake to stop vehicle. Engine exhaust brake is intended to
extend serviceable life of brake system components and engine exhaust brake disengages
when operator applies vehicle service brakes. Failure to comply may result in severe injury or
death to personnel and/or damage to equipment.
NOTE
For optimal braking performance, the exhaust braking device should be left on at all times.
The engine exhaust braking device operates only when the engine RPM is greater than 1000
RPM, and the driver’s foot is off the accelerator pedal and service brake pedal. This exhaust
braking device is linked to the transmission, activating a predetermined down shift of the
transmission upon activation of the exhaust braking device.
1. To engage the exhaust braking device, place the exhaust braking switch (1) in the up (ON) position. Engine
exhaust braking device will operate normally. The auxiliary brake indicator will illuminate on the annunicator
panel when active.
2. To disengage the exhaust braking device, place the exhaust braking switch (1) in the down (OFF) position.
Engine exhaust braking device will be disabled.
2-30
TM 9-2355-320-10
OPERATE AUTOMATIC FIRE SUPRESSION SYSTEM (AFSS)
WARNING
Do not have any open flame inside vehicle. An accidental discharge of fire bottles could result
causing severe injury or death.
get all soldiers out of vehicle as soon as possible.
Accidental discharge of fire bottles can seriously injure you. Deactivate fire suppression
system before you work near fire bottles. Remove and cap squib.
Accidental discharge of fire bottles can injure you. Remove vehicle ground cable and pull 5-
amp circuit breaker on Power Backup Unit (PBU) when maintaining fire suppression system.
Accidental discharge of fire bottles can seriously injure your eyes or skin. Wear face shield, ear
plugs, protective clothing, and gloves during fire bottle maintenance.
Engine fan can blow away fire suppression agent before fire is extinguished. Soldiers can get
burned. Equipment can get damaged. Stop engine before you operate engine fire suppression
system.
Stowed items can block fire suppression system outlets and prevent fires from being put out.
Ensure stowed items are kept clear of fire suppression system outlets and sensors.
4
1
1. AFSS displays and controls:

a. Power LED (4) – indicates power supply to the system.
b. Detection Fault LED (1) – indicates if there is a fault in any of the detectors or their circuitry.
c. Detection Alarm LED (2) – Flickering – pre alarm, steady – alarm and automatic activation of cylinders.
The LED blinks at pre-alarm level and lights in alarm level. Steady light indicates fire condition of optical
detector and cylinders activation. The LED lights in case that there is at least one detection signal.
d. Activation Switch (3) – enables a manual activation of the AFES system.
Built in Test (BIT): Control Box has a power-up built in test (PBIT) and continuous built in test (CBIT). Any faults
that are detected during the PBIT or CBIT are displayed on the control box (5) via the fault light (1).
2-31
TM 9-2355-320-10
OPERATE AUTOMATIC FIRE SUPRESSION SYSTEM (AFSS) - CONTINUED
MANUAL ACTIVATION OF ENGINE AFSS
WARNING
Engine fan can blow away fire suppression agent before fire is extinguished, causing severe
injury or death to personnel or damage to equipment. Stop engine before manually activating
fire suppression system. Evacuate vehicle immediately after manual activation.
To manually activate the engine compartment extinguisher cylinders, push the MANUAL ACTIVATION switch (3)
at the top of the control box (5).
1 4
2-32
TM 9-2355-320-10
ACTIVATION OF CREW COMPARTMENT AFSS
The AFSS Detection and Control Units (DCU) (1) uses optical sensors (2) to detect large fires and explosions
within 5 milliseconds. The DCU is also sensitive to small or growing fires. The DCU (1) will automatically
discharge the crew compartment AFSS when the system detects a fire. Manual activation of the crew
compartment AFSS is done by pushing the MANUAL ACTIVATION switch (3) on the DCU (1).
The green POWER LED (4) illuminates steadily when power is supplied to the AFSS DCU (1) and a yellow
FAULT LED (5) will flash if there is a fault in the crew compartment AFSS.
1
4
2-33
TM 9-2355-320-10
EXTERNAL EMERGENCY FIRE EXTINGUISHER SWITCH
1
3
1. Pull retaining pin (2) from cover plate (1) located at rear of vehicle underneath bustle box (3).
2. Swing plate (1) out of the way exposing the switch.
3. Press the exposed protected pushbutton.
4. All cylinders will discharge.
2-34
TM 9-2355-320-10
FUEL VEHICLE
WARNING
Diesel fuel is flammable. Wipe up fuel spills immediately. Shut off engine when fueling and do
not overfill tank. Do not smoke during fueling operations. Avoid operating electrical equipment
such as radios and personnel heaters while fueling. Failure to comply could result in
explosions and fire and cause serious injury or death to personnel and/or damage to
equipment.
1. Ground vehicle.
a. Install fueling vehicle ground wire to bare metal on the vehicle to be fueled.
2. Clean fuel filler area.

a. Remove any dirt and water around fuel filler cap. Use wiping rag.
3. Remove filler cap (2) from filler neck (1).
a. Lift lever on fuel filler cap (2) upward and rotate counterclockwise. Lift cap from neck.
2-35
TM 9-2355-320-10
FUEL VEHICLE - CONTINUED
CAUTION
Damaged fuel filler cap/seals or fuel filler neck clogged with dirt can cause fuel contamination.
4. Inspect and clean fuel filler neck:
a. Check fuel filler neck screen for installation and damage.
b. Remove any debris from fuel filler neck screen. If neck screen is damaged, notify Field Maintenance.
c. Check that fuel filler cap (2) and cover seals are not cracked, broken, or torn. If seals are damaged,
notify Field Maintenance.
d. Clean threaded part of fuel filler neck.
5. Fuel vehicle:
a. Insert fuel nozzle in fuel filler neck.
b. Fill fuel tank until fuel backs up into the fuel filler screen. Do not top off.
c. Remove fuel nozzle.
d. Use wiping rag to clean any spilled fuel.
6. Install fuel filler cap:
a. Place fuel filler cap in fuel filler neck and turn lever to clockwise to tighten.
b. Move fuel cap lever on fuel filler cap down into stowed position.
7. Remove fueling vehicle grounding wire.
2-36
TM 9-2355-320-10
STOW/UNSTOW FUEL AND WATER CANS
WARNING
Fuel and water cans are heavy when full. Use care when lifting the cans out of the racks.
NOTE
The vehicle is equipped with provisions to carry two military fuel/water cans. Mounts for two
cans are provided on the driver side, aft of the side door. Rear can cannot be removed until
front can has been removed.
Unstow
1. Release restraining straps securing can to hull.
2. Remove front can (1) by lifting slightly to clear tray (4) sides and move can towards front of vehicle and down
to clear effector armor module (2).
3. Place can on the ground. Repeat Step 2 to remove rear can (3) if necessary.
4. Raise tray (4) and secure with restraining straps to prevent damage from beating against the side of the
vehicle.
1 2
Stow
WARNING
Fuel and water cans are heavy when full. Use care when lifting the cans up to the racks.
1. Release restraining straps and lower trays (4).
2. Lift can (1, 3) behind effector armor module (2) and place in bracket (4).
3. Pass the restraining strap beneath the fuel/water (1, 3) can handles and above the body of the can.
4. Refasten restraining straps and tighten to prevent damage from beating against the side of the vehicle.
2-37
TM 9-2355-320-10
RAISE AND SECURE HOOD
1. Unlatch hood by releasing handles (1).
2. Remove prop rod from latch(2).

3. Place prop rod in hole (3).
2-38
TM 9-2355-320-10
LOCK AND UNLOCK STOWAGE BINS

1. Pull lock pin (1) and release rear brush guard latch mechanism (2).
2. Move brush guard (3) away from vehicle.
3. Unlock and remove padlock installed on stowage bin lock area (4).
4. Rotate handle (5) clockwise.
5. To lock the stowage bin, close stowage bin door and latch by rotating handle (5) counterclockwise.
6. Install padlock at lock area (4).
7. Move brush guard (3) back to vehicle and latch.
8. Install lock pin (1) into brush guard latch mechanism (2).
2-39
TM 9-2355-320-10
STOW SQUAD SEAT
WARNING
Rotating parts can move suddenly and can pinch or crush hands. Keep guards in place. Keep
clear of rotating parts.
1. Slide foot rest extension (1) into stowed position on foot rest assembly (2).
2. Raise foot rest assembly (2) and allow to collapse as seat pan (3) rises to stowed position.
2-40
TM 9-2355-320-10
RIFLE RACKS
The vehicle is equipped with two rifle racks, located behind the commander’s seat and driver’s seat. The racks
are designed to hold one standard U.S. Army rifle apiece.
Rifle rack behind Driver’s seat
Rifle rack behind Commander’s seat
2-41
TM 9-2355-320-10
OPERATING UNDER UNUSUAL CONDITIONS
WARNING
Vehicle control is greatly reduced when driving vehicle with a flat tire. Vehicle speed and
loading must be reduced, especially when traveling on secondary roads, cross-country, or with
traffic present. Failure to comply may result in severe injury or death to personnel and/or
damage to equipment.
When driving your vehicle, the existing conditions are constantly changing. Never drive at a
speed greater than is reasonable and prudent for these conditions. Loss of vehicle control will
occur, causing damage to equipment, and injury or death to personnel.
CAUTION
A wheel that has been run flat must be replaced as soon as possible before reuse, or damage to
equipment may result.
RUNFLAT OPERATION
The MRAP RG33L Plus is fitted with Variable Function Insert (VFI) G40 runflats, suitable for use with 16.00 R20
tires. The VFI runflat prevents the separation of the tire from the rim, and the airtight seal against the rim prevents
foreign matter such as sand and mud entering the tire, regardless of pressure, thus eliminating the use of
beadlocks.
2-42
TM 9-2355-320-10
MUD, SAND, AND SNOW
WARNING
Extreme care should be taken when entering unknown terrain. Deep water, snow, or soft
muddy conditions can hide obstructions such as rocks, logs, ruts, or holes. Hidden
obstructions can cause erratic movement of the vehicle and injury to personnel or damage to
equipment.
Whenever you are conducting operations in unknown terrain, and tactical situation permits,
close and secure roof hatch. Ensure that combat locks are engaged on doors and ramp to
ensure they do not accidentally open.
Approach grades with extreme care as they may be slippery and vehicle may lose traction,
causing injury to personnel or damage to equipment.
CAUTION
Move cautiously, especially where conditions under the driving surface are unknown.
Driving through water or on wet or muddy ground may affect brake performance. The vehicle
may not slow down at the expected rate, and may pull to the right or left.
Operation in Mud, Sand, and Snow
2. Engage All Wheel Drive (AWD).
3. Engage differential lock.
4. Engage low range.
5. Select appropriate gear range for conditions.
6. Release service brake.
CAUTION
Avoid sharp turns. Make gradual turns to maintain momentum. The vehicle may handle and
steer differently with the differential lock engaged.
If rear skidding occurs, let up on accelerator pedal and turn steering wheel in direction of skid
until control has been regained. Accelerate very gradually to prevent loss of traction. Slowly
depress brake pedal to prevent loss of traction.
7. Start out slowly.
8. Accelerate at a positive and slow pace, maintaining positive traction.
After Operation in Mud, Sand, and Snow
1. Clean wheels of mud, sand, or snow, if tactical conditions permit.
2. Check air cleaner restriction indicator for operating limits, if tactical conditions permit. If gauge reads in red
zone, notify Field Maintenance.
Operation in Terrain with Mud-filled Holes
CAUTION
Mud-filled holes should be avoided whenever possible if depth of holes is unknown.
Check depth of holes if situation permits. Make gradual turns to maintain momentum.
Vehicle may handle and steer differently in rough terrain.
2-43
TM 9-2355-320-10
MUD, SAND, AND SNOW - CONTINUED
NOTE
If necessary, select the Low Range on the transfer case.
CAUTION
Avoid sharp turns. Make gradual turns to maintain momentum. The vehicle may
handle and steer differently with the differential lock engaged.
7. Advance through mud-filled terrain until the third wheel begins to enter the mud.
8. If the front wheels have not submerged completely in the mud, slowly accelerate to gain momentum to exit
the hole.
9. If the front wheels have submerged, back out and find a different route.
10. Accelerate at a positive, careful, and slow pace, maintaining positive traction.
After Operation in Terrain with Mud-filled Holes
Clean wheels of mud, if tactical conditions permit.
UNUSUAL TERRAIN
WARNING
Extreme care should be taken when entering unusual and unknown terrain. Use extreme
caution when transporting personnel. Vehicle speed must be reduced consistent with weather
and road/terrain conditions. Hidden obstructions can cause erratic movement of the vehicle
and injury to personnel or damage to equipment.
Whenever you are conducting operations in unknown terrain, and tactical situation permits,
close and secure roof hatch. Ensure that combat locks are engaged on doors and ramp to
ensure they do not accidentally open, causing injury to personnel or damage to equipment.
Approach grades with extreme care, as they may be slippery and vehicle may lose traction,
When moving across a slope, choose the least angle possible, keep moving, and avoid turning
quickly. Do not travel diagonally across a grade unless it is absolutely necessary. Vehicle may
tip causing injury to personnel or damage to equipment.
When low range is used for engine braking while descending steep grades, do not exceed
engine governed speed or the transmission will upshift to the next higher range to prevent
engine damage. This will reduce engine braking and could cause a loss of control. Apply
vehicle brakes to prevent exceeding engine governed speed in the lower range selected.
2-44
TM 9-2355-320-10
UNUSUAL TERRAIN - CONTINUED
CAUTION
Move cautiously, especially while driving on unusual terrain. Before ascending or descending
steep hills, stop vehicle, place transmission in N (Neutral), and shift transfer case to low range.
Failure to shift transfer case to low range before ascending or descending steep hills may
damage the drivetrain.
Avoid sharp continuous turns. Make gradual turns to maintain momentum. The vehicle may
handle and steer differently with the differential lock engaged. Failure to avoid sharp
continuous turns while operating transfer case in low range may cause damage to drivetrain.
NOTE
Placing range selector in a lower gear will provide better speed control on rolling terrain.
4. Engage low range.
8. Accelerate at a positive and slow pace, maintaining positive traction.
2-45
TM 9-2355-320-10
FORDING
WARNING
Do not enter water where a bank has a gradient of 40% or greater. Vehicle may tip or begin
erratic movement causing injury to personnel or damage to equipment.
Check load distribution before water operations. Ensure all stowage items are properly
installed and secured. Incorrect distribution of cargo can cause vehicle to swamp. This may
cause erratic movement of vehicle and injury to personnel or damage to equipment.
Do not attempt to cross water if depth is deeper than 36 in. (91 cm). Vehicle may float, causing
erratic movement of vehicle and injury to personnel or damage to equipment. If in doubt,
confirm water depth.
Extreme care should be taken when entering unknown terrain. Deep water or soft muddy
conditions can hide obstructions such as rocks, logs, ruts, or holes. When approaching the
shore, do not drive over protruding objects such as rocks, logs, or stumps. Hidden objects can
cause erratic movement of vehicle and injury to personnel or damage to equipment.
Whenever you are conducting fording operations, and tactical situation permits, open and
secure roof hatch. Ensure that combat locks are engaged on doors to ensure they do not
accidentally open.
Ensure hull drain plug is in place and secure (5-9). Vehicle may take on water and swamp,
To prevent injury or death, do not wear seatbelts or shoulder harness when driving in water as
they can impede a quick exit from a sinking vehicle.
Do not enter grades that are slippery, as vehicle may lose traction, causing injury to personnel
or damage to equipment.
CAUTION
When entering and driving through water during fording operations, do not allow the wake at
the front of the vehicle to enter the air intake grille. Vehicle speed must be adjusted to prevent
water entering into the air intake grille. Water entering the air intake grille will result in the
engine stalling and may cause severe damage to the engine.
Driving through water, or on wet or muddy ground, may affect brake performance. Vehicle may
not slow down at the expected rate, and may pull to the right or left. After exiting water, brakes
should be applied two or three times to dry brake shoes.
After fording operations, check differentials for water contamination. If oil appears white or
discolored, notify Field Maintenance.
1. Before entering the water, perform the following:

a. Check to ensure hull drain plug is secured (5-9).
b. Ensure fuel cap is secure.
CAUTION
Depth should be determined prior to fording operations, if tactical situations permit.
2-46
TM 9-2355-320-10
FORDING - CONTINUED
2. Entering the water, perform the following:
a. Bring vehicle to a stop.
b. Engage All Wheel Drive (AWD).
c. Engage differential lock.
d. Engage low range.
e. Shift transmission selector to first gear.
CAUTION
If vehicle forward speed is too fast, water will rise over air intake and may cause
damage to the engine.
f. Increase engine speed to 950 RPM; maintain engine speed above 950 RPM.
g. Enter the water slowly.
h. Keep engine speed above 950 RPM. Drive 3 to 4 mph (5 to 6 kph) to prevent making a “bow wave.”
i. Accelerate at a positive and slow pace through the water, once vehicle is level.
3. Driving in and exiting the ford:
a. Advance at constant and slow forward speed on river or creek beds.
b. Approaching the shore, if possible, do not drive over protruding objects such as rocks, logs, stumps, etc.
c. Test/dry out brakes as soon as possible.
NOTE
These exit procedure checks should be made as soon as operational situation
permits.
4. Exit Procedures:
a. Check for oil and water seepage from differentials. Check to see if water has leaked into differentials by
checking for a white or discolored fluid from differential.
b. Drain the hull (5-9) by removing the drain hull plug and allowing excess water to drain out.
c. Using fresh water, flush salt water out of interior.
5. Lubricate the following:
a. Drive shafts (excluding the shaft between automatic transmission and the transfer case) should be
lubricated.
b. Lubricate towing pintle.
c. Check for leaks around doors.
δ. Ρεπορτ λεακσ το Φιελδ Μαιντενανχε.
2-47
TM 9-2355-320-10
REAR DOOR EMERGENCY OPERATION (NO ELECTRIC POWER AVAILABLE)
WARNING
Rear door is very heavy (1,400 lb [636 kg]) and difficult to operate without power assist. Get an
assistant to help or use a suitable lifting device when operating doors without power assist.
Failure to comply may result in severe injury or death to personnel.
EMERGENCY OPERATION - OPEN DOOR
NOTE
Rear door blast lock and door latch must be engaged prior to opening the door in emergency
conditions.
1
2
WARNING
Do not look into the openings of the valve bodies when performing steps 1 and 2 as the
escaping air can blow particulates into your eyes. Be sure to perform steps 1 and 2 in the
correct order. Failure to comply may result in severe injury or death to personnel.
1. Slowly rotate the handle of the left emergency exit valve (1) to a horizontal position. The air pressure in the
power assist door opening side will bleed off.
2. Slowly rotate the handle of the right emergency exit valve (2) to a horizontal position. The air pressure in the
power assist door closing side will bleed off.
3. Pull the blast lock handle to disengage the lock. 1
4. Rotate the door handle to unlatch the door.

2
5. Manually push door to the fully open position.
2-48
TM 9-2355-320-10
EMERGENCY OPERATION - CLOSE DOOR
WARNING
Remove all objects from the vicinity of the rear door when operating the door under emergency
conditions. Keep hands and arms away from the door when closing to avoid injury to
personnel or damage to equipment. Failure to comply may result in severe injury or death to
personnel.
NOTE
Rear door blast lock and door latch must be disengaged prior to closing the door in emergency
conditions.
1
2
WARNING
Do not look into the openings of the valve bodies when performing steps 1 and 2 as the
escaping air can blow particulates into your eyes. Be sure to perform steps 1 and 2 in the
correct order. Failure to comply may result in severe injury or death to personnel.
1. Verify the blast lock and door latch are disengaged.
2. Slowly rotate the handle of the right emergency exit valve (2) to a horizontal position. The air pressure in the
power assist door closing side will bleed off.
3. Slowly rotate the handle of the left emergency exit valve (1) to a 1
horizontal position. The air pressure in the power assist door

opening side will bleed off. 2
4. Manually pull the door closed.

5. Rotate the door handle to latch the door.
6. Push the blast lock handle to lock the door.
2-49
TM 9-2355-320-10
RESETTING POWER ASSIST SYSTEM (AFTER FOLLOWING EMERGENCY DOOR OPERATIONS AND
ELECTRIC POWER IS RESTORED)
WARNING
Remove all objects from the vicinity of the rear door when operating the door under emergency
conditions. Keep hands and arms away from the door when closing to avoid injury to
personnel or damage to equipment. Failure to comply may result in severe injury or death to
personnel. Perform rear door power assist reset from inside vehicle. Verify all personnel are
out of range of the door closing/opening path during power assist reset procedure.
1. Manually close door. Engage latch and blast lock to hold door in closed position.
2. Slowly rotate the handle on the right (door open) emergency exit valve (2) to a vertical position.
3. Slowly rotate the handle on the left (door close) emergency exit valve (1) to a vertical position.
1
2
4. Toggle the power door switch (3) on the control box to the “close” position and hold for 5-8 seconds. This will
re-pressurize the system.
5. Pull the blast lock handle to disengage the lock.
6. Rotate the door handle to counterclockwise to unlatch the door.
2-50
TM 9-2355-320-10
RESETTING POWER ASSIST SYSTEM (AFTER FOLLOWING EMERGENCY DOOR OPERATIONS AND
ELECTRIC POWER IS RESTORED) – CONTINUED
NOTE
Rear door will open and close rapidly until system has effectively reset itself.
7. Toggle the power switch to the open position and hold until door is fully open.
8. Toggle the power switch to the close position and hold until door is fully closed.
9. Repeat steps 7 & 8 until door operation is smooth and takes approximately 5 seconds to open and 5 seconds
to close.
EMERGENCY EVACUATION
NOTE
Combat lock release on side door shown without effector armor mounted.
Emergency rescue procedures from outside of vehicle require unlocking the combat
lock.
1. Insert ½ inch breaker bar into slot (1).
2. Turn breaker bar counterclockwise to unlock combat lock.
2-51
TM 9-2355-320-10
STOW/UNSTOW TOW BAR
WARNING
The tow bar is heavy and requires a two-person lift. The tow bar is mounted approximately 3 ft
(1 m) off the ground. Additionally, it is set back from the front of the vehicle. Care must be
exercised when dismounting the tow bar to avoid serious injury or damage to equipment.
NOTE
Not all MRAP RG33L Plus vehicles are equipped with a tow bar.
UNSTOW
1. Release restraining latches located on the cradle at each end.
2. With the assistance of another crew member or squad member, lift the tow bar out of the cradle and set it on
the ground.
3. Close the restraining latches.
STOW
1. Open latches located at the top of the cradle on each side of the front of the vehicle.
2. With the assistance of another crew member or squad member, lift the tow bar and place it in the cradle.
3. Secure the tow bar in place with the restraining latches provided.
2-52
TM 9-2355-320-10
CASEVAC AND LITTER DEPLOYMENT
1. Remove two locking pins (1) securing litter (2) to two stowage brackets (3).
2. Remove litter (2) from brackets (3).
3. Remove eight screws (4) and flat washers (5) from the backs of forward and rear facing seats (6). Save the
screws and washers for reuse.
4,5 4,5
2-53
TM 9-2355-320-10
CASEVAC AND LITTER DEPLOYMENT - CONTINUED
4. Fold footrest (3) across seat (1) and secure with 5 point seatbelt (2) as shown.
2
1
5. Install folded seats (1) to floor of vehicle over ammo brackets as shown.
6. Secure both seats (1) face down to floor in a crosswise pattern using ammo bracket straps (2) to secure.
2-54
TM 9-2355-320-10
CAUTION
CASEVAC mount assembly weighs 35 lb (16 kg). If necessary, get help prior to lifting
CASEVAC mount out of NBC box.
7. Remove CASEVAC mount (7) by disengaging two locking pins (8) at bottom of CASEVAC mount.
8. Lift CASEVAC mount (7) and pull away from hull until clear of two hangers (9).
7
9
2-55
TM 9-2355-320-10
9. Lay the CASEVAC mount (7) on the ground with the tube handle (10) facing up.
THIS SIDE DOWN

TUBE HANDLE
FACES UP
10
10. To disassemble CASEVAC mount (7), remove four mounting bolts (11) and tube handle assembly (10) from
CASEVAC mount.
11. Remove two straps (12) from around CASEVAC mount (7).
12
10
11
2-56
TM 9-2355-320-10
12. Remove bolt (13) from bottom of CASEVAC mount (7).
13
13. To assemble CASEVAC mount (7) for use, remove two pins (14) from mount and remove litter mount (15)
from main mount (16).
7
14
16
15
2-57
TM 9-2355-320-10
14. Install litter mount (15) onto main mount (16) using two bolts removed from tube handle assembly.
15. Tighten mounting bolt.
16. Repeat steps 11-13 for remaining mount.
16
15
MOUNTING BOLT REMOVED

FROM TUBE ASSEMBLY
17. Install two assembled CASEVAC mount assemblies (17) to seat mount bracket assembly (18) using eight
screws and washers removed in step 3.
18. Install eight screws (4) and washers (5) and hand tighten.
19. Tighten screws (4).
20. Ensure litter pins (19) at each corner of CASEVAC mount assemblies (17) are loose and disengaged.
17
18
4, 5
19
2-58
TM 9-2355-320-10
21. Mount litter (20) onto CASEVAC mount assemblies by aligning four litter feet (21) onto each side of two litter
mounts (one side shown).
22. Make sure all four litter feet (21) align properly and secure litter feet to two litter mounts with four litter pins
(19).
20 21
19
2-59
TM 9-2355-320-10
START VEHICLE WITH OUTSIDE POWER SOURCE
WARNING
Remove all jewelry before conducting maintenance. Do not wear watches, rings, dog tags, or
other jewelry which could short across electrical components or catch on vehicle components.
Failure to comply may result in severe injury or death to personnel.
1. Prepare disabled vehicle for Slave-Start:
CAUTION
Do not attempt to start a vehicle engine by pushing or towing vehicle, as damage may occur to
vehicle transmission or transfer case.
a. Ensure all electrical equipment is turned off in disabled vehicle.
b. Ensure Master Power switch (1) is set to the OFF position in disabled vehicle.
c. Remove slave receptacle protective cap (1).
2. Prepare serviceable vehicle:

a. Move serviceable vehicle along side of disabled vehicle.
b. Place gear range selector to Neutral (N) position.
c. Apply parking brake on serviceable vehicle.
d. Remove slave receptacle protective cover.
2-60
TM 9-2355-320-10
START VEHICLE WITH OUTSIDE POWER SOURCE - CONTINUED
3. Connect slave cable to vehicles:
a. Remove slave cable from stowed location.
b. Remove protective caps from slave cable ends.
c. Connect slave cable end to slave receptacle on disabled vehicle.
d. Connect opposite end of slave cable to slave receptacle on serviceable vehicle.
e. Toggle the NATO select switch (1) on the center dash auxiliary panel to ON for disabled vehicle.
f. Toggle NATO select switch on serviceable vehicle to ON position.
g. Increase engine RPM to 1200 on serviceable vehicle.
h. Start disabled vehicle and remove slave cable.
4. Allow a minimum five minutes for disabled vehicle batteries to become partially charged.
NOTE
Charging time should be increased in cold weather. The colder the temperature, the longer the
charging time should be.
If batteries are severely discharged, ensure voltmeter shows signs (slight increase on
voltmeter) of accepting a charge before attempting to start.
5. Verify the following gauge indications after engine start:

a. Ensure voltmeter gauge indicates alternator output between 23-28 volts.
b. Increase engine RPM to 1200 after engine idle has stabilized at 650-700 RPM and oil pressure has
stabilized at 5-87 psi (34-600 kPa).
6. Put NATO select switch on both vehicles to OFF position.
2-61
TM 9-2355-320-10
CHAPTER 2 – OPERATOR INSTRUCTIONS
PREPARING DISABLED VEHICLE FOR TOWING OPERATIONS
Front Lift Tow – Like Vehicle Recovery Operations
WARNING
Use two ground guides to aid driver in backing vehicle. Inadequate guidance during backing
operation may result in accidental impact, causing serious injury or death to personnel or
damage to equipment.
NOTE
Like vehicle towing must be accomplished using vehicle of equal or greater weight.
1. Back towing vehicle up so that it is aligned with disabled vehicle as necessary.

2. Stop vehicle.
3. Set emergency brake.
WARNING
The tow bar is heavy and requires a two person lift. The tow bar is mounted approximately 3 ft
(1 m) off the ground. Additionally it is set back from the front of the vehicle. Care must be
exercised when dismounting the tow bar.
4. Unstow tow bar (page 2-52)

5. Install the two pin adapters (1) to the lifting lugs (2) on the front of the disabled vehicle.
6. Install the tow bar (5) to the pin adapters (1) with two pins (3) and cotter pins (4).
1 3, 4
2-62
TM 9-2355-320-10
PREPARING DISABLED VEHICLE FOR TOWING OPERATIONS – CONTINUED
WARNING
Do not put hands near pintle hook when aligning lunette eye with pintle hook. Failure to comply
may result in serious injury or death to personnel.
7. Install the lunette eye (1) of the towbar (3) to the pintle hook (2) of the towing vehicle.
8. Close latch of tow pintle and secure with safety pin.
1, 2
3
9. Install air lines, electrical cable(s), safety pins, and safety chains (4). Leave sufficient slack in safety chains to
allow for turns. Install tow lights.
NOTE
Drive shaft must be removed if transfer case will not shift into neutral.
10. Place transfer case in neutral.
NOTE
If the air supply on the casualty vehicle will not hold air, call for wrecker support.
11. Push in the trailer air supply control on the recovery vehicle.
12. Push in the parking brake control on the disabled vehicle.
13. Recheck towing connections, air lines, and chains.
14. Tow disabled vehicle. Use speeds appropriate for conditions and avoid sharp turns.
2-63
TM 9-2355-320-10
Dedicated Recovery, Front Lift Tow
NOTE
If casualty vehicle has no air pressure, the rear brakes will need to be caged (page 5-1).
WARNING
Do not use MTVR Wrecker to front lift tow the MRAP RG33L Plus Cat II; vehicle exceeds the
retrieval system lift capacity.
1. Install appropriate retrieval system adapters. Using cylinder controls, lower the cross tube (1) to
approximately 3 ft (1 m) off the ground.
2. Using ground guides, slowly back the recovery vehicle and connect retrieval system to the disabled vehicle. If
using Multi-Use Adapter (MUAs), use 1-1/2 in. (3.8 cm) pin hole number 6.
3. Route chains around the front axle and connect to hook on the appropriate adapter.
2-64
TM 9-2355-320-10
WARNING
Vehicles with catastrophic damage to the front axle and suspension may require the axle to be
properly secured to the chassis for safe recovery of the vehicle. Never attach safety chains to
axles or suspension components that are no longer physically attached to the vehicle. Never
cross the safety chains.
2 1 3
4. Hook safety chain (1) around frame or front axle and connect to rear tow shackles or safety chain loop on
wrecker. Ensure sufficient slack in safety chains to allow for turns.
5. Install air lines (2), electrical cable(s) (3), and safety pins.
6. Install tow lights. Check rigging.
7. Place transfer case in neutral. Drive shaft must be removed if transfer case will not shift into neutral.
8. Push in the trailer air supply control on the recovery vehicle.
9. Push in the parking brake control on the disabled vehicle.
10. Raise vehicle so front wheels are 6-12 inches above ground, depending on terrain.
11. Recheck towing connections, air lines and chains.
2-65
TM 9-2355-320-10
Dedicated Recovery, Rear Lift Tow
WARNING
Recovering this vehicle from the rear should be performed only in emergency combat
situations, and with the commander’s approval. Decrease speeds and be extremely cautious.
WARNING
Vehicles with catastrophic damage to the rear axle(s) and suspension may require the axle to
be properly secured to the chassis for safe recovery of the vehicle. Never attach safety chains
to axles or suspension components that are no longer physically attached to the vehicle. Never
cross the safety chains.
WARNING
Do not use MTVR Wrecker to rear lift tow the BAE Cat I and II, vehicle exceeds the retrieval
system lift capacity.
NOTE
Remove rear step
1. Straighten and secure steering wheel before towing.

2. Install appropriate retrieval system adapters. Using cylinder controls, lower the cross tube to approximately 3
ft (1 m) off the ground.
3. Using ground guides, slowly back the recovery vehicle. Connect the retrieval system MUA adapters using a
1½ in. (3.8 cm) pin through hole number 4 and connect to the rear tow lugs of the disabled vehicle.
4. Route chains around the rear axle and connect to hook on the adapter.
5. Hook safety chains around rear axle and connect to rear tow shackles or safety chain loop on wrecker.
6. Install air lines and tow lights. Leave sufficient slack in safety chains to allow for turns.
7. Install tow lights. Check rigging.
8. Raise vehicle so rear wheels are 6-12 in. (15.2-30.5 cm) above ground, depending on terrain.
9. Recheck towing connections, air lines and chains.
2-66
TM 9-2355-320-10
EQUIPMENT DATA TABLES
Equipment Data Table
Tow Bars and Adapters
Tow Bar NSN Type Adapter NSN Tow Bar Capacity

2540-01-267-2912 V- type, light , NSN 2540-00-863-3153 112,000 lb (50,848
medium, and kg)
US ARMY heavy duty 2 ½-10 Ton (2.3-9 mt) M88A1
Light duty GVW
US Army/USMC Wreckers
Model GCWR VCW Max Flat Tow Weight Under Lift
114,000 lb 50,900 lb
M984A2 (51,756 kg) (23,109 kg) 63,100 lb (28,647 kg) 25,000 lb (11,350 kg)
98,100 lb 48,800 lb
MK 36 (44,537 kg) (22,155 kg) 49,300 lb (22,382 kg) 14,000 lb (6,356 kg)
USMC MTVR Tow bar kit, NSN 2350-01-496-8356
2-67
TM 9-2355-320-10
US Army Tow Bar, NSN 2540-01-267-2912
References
FM 21-305, Manual for the Wheeled Vehicle Driver
FM 4-30.31, Recovery and Battle Damage Assessment and Repair
TB 9-2320-279-12-1, Operator Maintenance Component of End Item (COEI) for MUA parts
TC 43-35, Recovery and Training
TM 10867B-12&P, Operator Manual for Medium Duty Tow Bar Kit (USMC)
TM 9-2320-279-10-1, M977 Series, 8x8 Heavy Expanded Mobility Tactical Trucks HEMTT
TM 9-2320-279-10-2, M977 Series, 8x8 Heavy Expanded Mobility Tactical Trucks HEMTT
TM 9-2355-108-10, BAE Systems, RG33 and RG33L Operator Manual COTS
2-68
TM 9-2355-320-10
CHAPTER 3 – TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM INDEX
The Troubleshooting Symptom Index lists common malfunctions that may occur during operation or crew
servicing of the vehicle and its components.
The Troubleshooting Symptom Index is divided into sections. Each section covers malfunctions common to the
different systems of the vehicle.
Identify the malfunction that best describes the problem and turn to the appropriate Troubleshooting Table.
TROUBLESHOOTING TABLES
The Troubleshooting Tables contain tables listing the malfunctions, tests or inspections, and corrective actions
required to return the systems to normal operation. Perform the steps in the order they appear in the tables.
The Troubleshooting Tables contain three columns: MALFUNCTION, TEST OR INSPECTION, and
CORRECTIVE ACTION.
Malfunctions (symptoms) are listed in sequence through the Troubleshooting Table.
The test or inspection is a step to perform to help isolate the fault that causes the malfunction. Each test or
inspection has a corrective action.
Corrective actions are statements that tell what to do in order to correct the fault.
This manual cannot list all possible malfunctions, nor all the tests or inspections and corrective actions. It is
essential to record all faults and report them to Field Maintenance. If a malfunction is not listed, or is not corrected
by the listed corrective action, notify Field Maintenance.
3-1/3-2 blank
TM 9-2355-320-10
CHAPTER 3 – TROUBLESHOOTING PROCEDURES - CONTINUED
ENGINE
ENGINE DOES NOT CRANK ................................................................................................................................. 3-5
ENGINE CRANKS SLOWLY, BUT WILL NOT START .......................................................................................... 3-5
ENGINE CRANKS EASILY, BUT WILL NOT START ............................................................................................ 3-5
ENGINE STARTS, BUT RUNS ROUGH, ERRATIC, MISSES, STALLS, OR LOSES POWER............................ 3-6
ENGINE OVERHEATS ........................................................................................................................................... 3-6
ENGINE LOW OIL PRESSURE LIGHT COMES ON ............................................................................................. 3-7
EXCESSIVE BLACK, GRAY OR BLUE SMOKE.................................................................................................... 3-7
ENGINE OIL DILUTED WITH COOLANT OR FUEL.............................................................................................. 3-7
VOLTAGE GAUGE SHOWS LOW CHARGING RATE ..........................................................................................3-8
VOLTAGE GAUGE SHOWS EXCESSIVE CHARGING RATE.............................................................................. 3-8
ENGINE MALFUNCTION INDICATOR LAMP ILLUMINATES (AMBER OR RED) ............................................... 3-8
TRANSMISSION
TRANSMISSION DOES NOT SHIFT INTO ANY RANGE ..................................................................................... 3-8
TRANSMISSION SLIPS IN ALL RANGES ............................................................................................................. 3-9
TRANSMISSION SHIFTS ROUGHLY .................................................................................................................... 3-9
TRANSMISSION TEMPERATURE GAUGE AND INDICATOR SHOW OVER HEAT CONDITION ..................... 3-9
TRANSMISSION MALFUNCTION INDICATOR ILLUMINATES ............................................................................ 3-9
TRANSFER CASE
TRANSFER CASE NOISE.................................................................................................................................... 3-10
FAILURE TO SHIFT RANGES OR MODES......................................................................................................... 3-10
BRAKE SYSTEM
PARK/EMERGENCY BRAKE WARNING LIGHT IS ON...................................................................................... 3-10
ABS WARNING LIGHT IS ON .............................................................................................................................. 3-10
SERVICE BRAKING ACTION IS WEAK .............................................................................................................. 3-10
BRAKE AIR SYSTEM WILL NOT PRESSURIZE ................................................................................................. 3-11
SUSPENSION AND STEERING SYSTEM

VEHICLE IS HARD TO STEER OR DRIFTS TO SIDE ........................................................................................ 3-12
WHEELS VIBRATE SEVERELY .......................................................................................................................... 3-12
EXHAUST SYSTEM
EXHAUST FUMES IN CREW COMPARTMENT.................................................................................................. 3-13
PERSONNEL HEATER
PERSONNEL HEATER DOES NOT START........................................................................................................ 3-13
RESTRICTED PERSONNEL HEATER AIR FLOW.............................................................................................. 3-13
PERSONNEL HEATER DOES NOT PUT OUT ENOUGH HEAT ........................................................................ 3-13
PERSONNEL HEATER OVERHEATS AND STOPS ...........................................................................................3-13
PERSONNEL HEATER OVERHEATS AND DOES NOT STOP..........................................................................3-14
PERSONNEL HEATER INDICATES DIAGNOSTIC FAULT ON DISPLAY ......................................................... 3-14
AUTOMATIC FIRE SUPPRESSION SYSTEM

CONTROL BOX POWER LAMP DOES NOT ILLUMINATE ................................................................. …………3-14
YELLOW FAULT DETECTION LAMP ILLUMINATED ON CONTROL BOX ....................................................... 3-15
YELLOW FAULT DETECTION LAMP ILLUMINATED ON OPTICAL SENSOR.................................................. 3-15
3-3/3-4 blank
TM 9-2355-320-10
ENGINE
MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION
Engine does not crank. 1. Transmission not in neutral. Place transmission in neutral to
start.
WARNING
Contact with energized electric
circuits can kill or seriously
injure personnel. Disconnect
battery ground cables when
working on electrical system.
Remove rings and jewelry.
2. Check all circuit breakers on If circuit breakers are tripped, reset.

Power Distribution Center (PDC). If circuit breaker will not reset, notify
Field Maintenance.
3. Check voltage gauge for battery Attempt to slave start vehicle. If

charge level. Nominal battery vehicle starts, continue operation. If
charge is 24 - 28 VDC. vehicle does not start, notify Field
Maintenance.
4. Inspect battery cable clamps for Clean and tighten battery cable
looseness and corrosion. clamps.
WARNING
Engine cranks slowly, but will not 1. Attempt to slave start vehicle. If vehicle starts, continue operation.
start. If vehicle does not start, notify Field
Maintenance.
WARNING
Personnel may be exposed to
toxic materials during
maintenance. Wear gloves and
eye protection to prevent injury.
Engine cranks easily, but will not 1. Check fuel gauge and perform Add fuel.
start. visual inspection inside fuel tanks to
check fuel quantity.
2. Check fuel tanks and lines for Notify Field Maintenance if any
leaks or blockage. damage or vehicle will not start.
3. Observe air cleaner restriction Check air induction system and air
gauge for proper air flow. cleaner filter element for
obstructions. If clogged, remove
4. Check fuel shut off valve (3 ea) obstruction or replace air filter
under dash, at fuel tank cross over element.
lines, and at fuel tank.
3-5
TM 9-2355-320-10
ENGINE – Continued
WARNING
Engine starts, but runs rough, 1. Check to see if water-in-fuel Drain water from fuel/water
erratic, misses, stalls, or loses indicator illuminated. separator. Notify field maintenance
power. if indicator remains illuminated.
2. Check air cleaner restriction Check air induction system and air
gauge for proper flow. cleaner filter element for
obstruction or replace air filter
element.
WARNING
Hot parts can burn you. Allow
parts to cool before working on
or near them.
If necessary, use heat protective
gloves to work on hot parts.
3. Inspect exhaust system for Notify Field Maintenance of any

damage or restrictions. damage or restrictions.
WARNING
WARNING
Hot coolant can burn you. Do
not remove radiator cap until
coolant temperature gauge reads
in bottom one-quarter of green
zone. Use heat protective
mittens to turn radiator cap.
Turn cap slowly to release
pressure.
Engine overheats. 1. Check engine sure tank indicator Add coolant as needed.
to see if coolant level is low.
Inspect hoses and engine for
coolant leaks; notify Field
Maintenance if coolant leak found.
3-6
TM 9-2355-320-10
ENGINE - Continued
WARNING
Rotating parts can move
suddenly and can pinch or crush
hands. Keep guards in place.
Keep clear of rotating parts.
Engine overheats (Continued). 2. Check to see if engine cooling Shut down engine. Remove
fan is rotating and there are no obstructions from grill and radiator
obstructions such as mud or debris fins. Notify Field Maintenance if
at intake grill and radiator. engine cooling fan is not
operational.
3. Check engine drive belt for Notify Field Maintenance if belt is

looseness, cracks, damaged or loose, broken or damaged.
broken.
WARNING
Engine low oil pressure light comes 1. Check engine oil level. Add oil as needed.
on.
2. Check for engine oil leaks at Add oil as needed. Notify Field
filter, lines, and gaskets. Maintenance of engine oil leak.
Excessive black, gray or blue 1. Observe air cleaner restriction Check air induction system and air
smoke. gauge for proper air flow. cleaner filter element for
obstruction or replace air filter
element.
2. Check air induction system for Tighten loose air induction system
loose connections, missing or connections. Notify Field
damaged piping. Maintenance of any damage air
induction system components.
WARNING
WARNING
Hot coolant can burn you. Do
not remove radiator cap until
coolant temperature gauge reads
in bottom one-quarter of green
zone. Use heat protective
mittens to turn radiator cap.
Turn cap slowly to release
pressure.
3-7
TM 9-2355-320-10
ENGINE - Continued
Engine oil diluted with coolant or Check coolant surge tank and Notify Field Maintenance if cross-
fuel. engine oil for cross contamination. contamination exists.
Voltage gauge shows low charging 1. Listen and visually inspect engine Notify Field Maintenance.
rate (below 22 VDC). drive belt for looseness.
WARNING
2. Inspect battery cable clamps for Clean and tighten battery cable
looseness and corrosion. clamps.
WARNING
3. Do not operate engine. Notify Field Maintenance if belt is

loose, damaged, or broken.
Voltage gauge shows excessive Do not operate engine. Notify Field Maintenance.
charging rate (Above 28 VDC).
Engine malfunction indicator lamp Both malfunction indicator lamps Notify Field Maintenance if indicator
illuminates (amber or red). will illuminate at vehicle power up. remains illuminated or illuminates
during vehicle operation.
TRANSMISSION
WARNING
Transmission does not shift into any Check transmission fluid level. Add fluid as needed. Check for
range. leaks at transmission cooler, lines,
and transmission. Notify Field
Maintenance of any fluid leaks or if
transmission will not shift or if fluid
is too high.
If transmission continues to not

shift, notify Field Maintenance.
3-8
TM 9-2355-320-10
TRANSMISSION - Continued
WARNING
Transmission slips in all ranges. Check transmission fluid level. Add fluid as needed. Contact Field
Maintenance if transmission
continues to slip.
WARNING
Transmission shifts roughly. 1. Check transmission fluid level. Add fluid as needed. Check for
leaks at transmission cooler, lines,
and transmission. Notify Field
Maintenance of any fluid leaks or if
fluid level is too high.
2. Check for transmission Notify Field Maintenance if lamp is

malfunction indicator lamp. illuminated.
WARNING
Transmission temperature gauge 1. Stop vehicle immediately, but Add fluid as needed. Check for
and indicator show overheat keep engine running. If leaks at transmission cooler, lines,
condition. temperature decreases, continue and transmission. Notify Field
operation. If temperature does not, Maintenance of any fluid leaks or
proceed to Step 2. overheat condition persists.
2. Check transmission fluid level.
WARNING
3. Check engine cooling fan for If fan does not operate, notify Field
operation. Maintenance.
Transmission malfunction indicator Transmission malfunction indicator Notify Field Maintenance if indicator
illuminates. will illuminate at vehicle power up. remains illuminated or illuminates
3-9
TM 9-2355-320-10
TRANSFER CASE
Transfer case noise. 1. Driveline binding. Do not operate transfer case in
AWD unless traction required.
Notify Field Maintenance if
condition persists.
2. Shift through ranges and neutral; If uncorrected, notify Field

test operation. Maintenance.
WARNING
Air system operates at 120 psi
(828 kPa). This pressure will
damage eyes and cause bodily
injury. Always drain air tanks
before working on any part of air
system. Leave system open until
work is complete to prevent
accidental charging. Failure to
comply may result in severe
injury or death to personnel.
Failure to shift ranges or modes. 1. Vehicle not at complete stop. Bring vehicle to complete stop and
attempt to shift range or mode.
Shift from drive to neutral and back
to drive after selecting mode.
2. Driveline bind preventing shift. Operate vehicle reverse and

forward 50 yards (15 m) and
attempt to shift range or mode.
Notify field maintenance if transfer
case will not shift.
3. Check air pressure level gauge Notify Field Maintenance if air

for low air pressure or pressure system will not build or maintain air
loss. pressure of 120 psi (828 kPa).
BRAKE SYSTEM
Park/Emergency brake warning Check that parking brake is off. Notify Field Maintenance if light
light is on. stays on with released parking
brake.
ABS warning light is on. ABS light will illuminate at vehicle Notify Field Maintenance if indicator
power up. remains illuminated or illuminates
WARNING
Brakes can catch fire. Keep
brakes clean of flammable
materials.
Service braking action is weak. Check for wet brakes. Apply brakes two to three times with
vehicle moving at a slow speed to
dry brake pads. Notify Field
Maintenance if problem continues.
3-10
TM 9-2355-320-10
BRAKE SYSTEM - Continued
WARNING
Do not operate vehicle with low

air pressure. Vehicle brakes will
not work. Ensure air pressure
gauge remains in normal
operating range. Rapid, repeated
operation of the brakes may
deplete compressed air
reservoirs. Loss of air pressure
will cause the emergency brakes
to engage. Failure to comply
may result in injury to personnel
or damage to equipment.
Brake air system will not pressurize 1. Engine must be running to Start engine to pressurize the
or low air pressure warning remains pressurize the system. system. Notify Field Maintenance if
illuminated. system does not pressurize.
WARNING
Compressed air can injure you.
Do not aim compressed air at
yourself or other personnel.
Always wear goggles when
working with compressed air. Do
not use more pressure than 30
psi (207 kPa) with air nozzles.
2. Perform audible check to make Close air tank drain valves. Notify
sure air service tank drain valves Field Maintenance if air tanks drain
are closed. does not close.
3. Check service brake air hoses Check compressor, tank, valves,

and fittings. hoses and fittings for leaks with
soapy water and audible check.
Notify Field Maintenance of any
leaks or if system will not build
pressure.
3-11
TM 9-2355-320-10
SUSPENSION AND STEERING SYSTEM
WARNING
Low tire air pressure may lead to
tire failure, loss of vehicle
control, or rollover. Check tires
for proper inflation prior to
vehicle operation.
Vehicle is hard to steer or drifts to 1. Check for flat or damaged tire. Notify Field Maintenance for flat or
side. damaged tires.
2. Check tires for correct air Inflate tires to correct air pressure
pressure. for conditions.
WARNING
3. Check power steering for correct Add power steering oil as needed.
oil level. Inspect reservoir, power steering
hoses and cooler for leaks or visible
damage. Notify Field Maintenance
of any leaks or equipment failure.
WARNING
Wheel may be lost from vehicle
resulting in loss of vehicle
control/ rollover. Torque lug nuts
per Maintenance section
(Chapter 5).
WARNING
Low tire air pressure may lead to
tire failure, loss of vehicle
control, or rollover. Check tires
for proper inflation prior to
vehicle operation.
Wheels vibrate severely.
1. Check lug nuts for tightness. Tighten lug nuts per Maintenance
section (Chapter 5).
2. Check tires and wheels for Clean off debris. Replace damaged
damage, excessive wear, or debris wheel assembly.
buildup. Notify Field Maintenance of any tire
failure.
3-12
TM 9-2355-320-10
EXHAUST SYSTEM
WARNING
or near them. If necessary, use
heat protective gloves to work on
hot parts.
Exhaust fumes in crew 1. Vehicle doors open or not fully Do not operate engine with vehicle
compartment. closing. doors open. Stop engine. Turn
vent fan ON and allow exhaust
fumes to purge.
2. Check exhaust system for Notify Field Maintenance if doors

damaged components or loose will not close or if exhaust fumes
Exhaust system noisy. exhaust pipe connections. persist.
Check exhaust system for damaged Notify Field Maintenance of any

components or loose exhaust pipe exhaust leaks or damage.
connections.
PERSONNEL HEATER
Personnel heater does not start. 1. Personnel heater will not operate
at high ambient temperature.
Ensure ambient temperature is
below 90° F (32.2° C).
2. Ensure heater fuel supply valve Open fuel valve at personnel heater
is open. fuel pump.
WARNING
or near them. If necessary, use
heat protective gloves to work on
hot parts.
3. Check heater inlet and outlet Remove obstruction. If obstruction

ducts for obstruction. is not present, notify Field
Maintenance if personnel heater will
not start.
Restricted personnel heater air flow. 1. Check position of personnel Place HI/LO switch in HI position for
heater HI/LO switch. increased air flow.
2. Check heater inlet and outlet Remove obstruction. If obstruction

ducts for obstruction. is not present, notify Field
Maintenance.
Personnel heater does not provide Check position of personnel heater Place HI/LO switch in HI position for
enough heat. HI/LO switch. increased heating capacity.
3-13
TM 9-2355-320-10
Personnel heater overheats and Check heater inlet and outlet ducts Remove obstruction. If obstruction
stops. for obstruction. is not present, notify Field
Maintenance.
Personnel heater overheats and No Test. Turn off heater at control box. Turn
does not stop. off fuel supply valve at personnel
heater fuel pump. Notify Field
Maintenance.
Personnel heater indicates Check diagnostic display against If “C1” or “C2” fault is present,
diagnostic fault on display. codes listed on doghouse. replace igniter (see TM 9-2540-207-
14&P). If any other code, turn off
heater at control box. Turn off fuel
supply valve at personnel heater
fuel pump. Notify Field
Maintenance.
AUTOMATIC FIRE SUPPRESSION SYSTEM

WARNING
Control box green POWER lamp 1. Make sure Master Power switch Turn Master Power switch to ON
does not light. is in ON position. position. Notify Field Maintenance if
POWER lamp fails to light.
2. Check condition of maintenance Pull maintenance circuit breaker if

circuit breaker on backup power tripped. Notify Field Maintenance if
supply. circuit breaker remains tripped.
WARNING
Accidental discharge of fire
bottles can seriously injure
personnel. Deactivate fire
suppression system before
working near fire bottles.
Remove and cap squib.
Control box green POWER lamp 1. All lamps will flash for 7 seconds Notify Field Maintenance if POWER
flashes. at application of power. lamp continues to flash.
2. Check voltage gauge for battery Nominal battery charge is 24 - 28

charge level. VDC. Attempt to start vehicle. Notify
Field Maintenance if POWER lamp
continues to flash after vehicle start.
3-14
TM 9-2355-320-10
AUTOMATIC FIRE SUPPRESSION SYSTEM - Continued
WARNING
Accidental discharge of fire
bottles can seriously injure
personnel. Deactivate fire
suppression system before
working near fire bottles.
Remove and cap squib.
WARNING
Fire suppression agent can
irritate your throat and eyes.
Prolonged exposure can make
you dizzy. After discharging fire
suppression system, open hatch
covers and turn on vent fans, and
get all personnel out of vehicle as
soon as possible.
Yellow FAULT detection lamp is Count number of flashes. Notify Field Maintenance of FAULT
illuminated on control box. lamp condition and number of
flashes.
CAUTION
Do not use something other than
lens paper to clean optical sensor
window. Failure to comply may
result in damage to optical
sensor.
Yellow FAULT detection lamp is Count number of flashes. Clean optical detection windows in
illuminated on optical sensor. crew compartment if FAULT lamp
blinks four (4) times. Notify Field
Maintenance of FAULT lamp
condition for all other fault conditions
or fault condition persists.
3-15/3-16 blank
TM 9-2355-320-10
CHAPTER 4 – PMCS MAINTENANCE INSTRUCTIONS
Chapter 4 - PMCS MAINTENANCE INSTRUCTIONS
4-1. OPERATOR/CREW MAINTENANCE GENERAL INFORMATION
To ensure the vehicle is ready for operation at all times, it must be inspected on a
regular basis so items to be serviced may be found before they result in serious
damage, equipment failure, or injury to personnel. This chapter includes
Operator/Crew instructions for Preventive Maintenance Checks and Services
(PMCS) necessary to maintain the vehicle.
4-2. GENERAL MAINTENANCE PROCEDURE

(a) Cleanliness
Dirt, grease, oil, and debris get in the way and may cover up a serious problem.
(b) Lubrication
General lubrication requirements for the vehicle are listed in the Lubrication
Appendix (B).
(c) Nuts and Screws

Check for obvious looseness, missing, bent, or broken conditions. You cannot
try them all with a tool, but look for chipped paint, bare metal, or rust around
screw heads. If you find a screw or nut you think is loose, tighten it or report it to
Field Maintenance.
(d) Welds
Look for loose or chipped paint, rust, or gaps where parts are welded together.
If you find a cracked weld, report it to Field Maintenance.
(e) Electrical Wires and Connectors

Look for cracked or broken insulation, bare wires, and loose or broken
connectors. Tighten loose connectors and make sure the wires are in good
shape. If you find damaged wires or connectors, or any electrical system
operating intermittently, report it to Field Maintenance.
(f) Fluid Lines, Fittings and Air Lines

Look for wear, damage, or leaks, and make sure clamps and fittings are tight.
Wet spots show leaks, but a stain around a fitting or connector can also identify
a leak. If a leak comes from a loose fitting or connector, tighten it. Start vehicle,
let air tanks fill, shut off engine, and listen for air leaks. If any part is broken or
worn out, start vehicle, listen for air leak, and report it to Field Maintenance.
(g) Damage
Damage is defined as any condition that affects safety or would render the
vehicle unserviceable for mission requirements.
4-1
TM 9-2355-320-10
(h) Corrosion Control
Corrosion control maintenance is a requirement of the vehicle. WHILE
PERFORMING YOUR PMCS, look for and always be aware of rust, paint
peeling, blistering, damage that can cause corrosion, or other signs of
corrosion. Inspect the entire vehicle as well as the specific areas mentioned in
the PMCS. Also look for and always be aware of missing or damaged corrosion
preventive compounds. Report problem areas as soon as possible to Field
Maintenance. Having problem areas corrected as soon as possible will
maximize the life of the vehicle.
Appearance and color of corrosion is dependent on the metal/components

involved. The following information listed in visual Detection of Corrosion Table
will aid in the visual detection of corrosion.
Visual Detection of Corrosion Table
Metal/Component Corrosion
Steel Powdery, Reddish-Brown
Film
Aluminum Powdery, White Film
Brass Green Film
Electrical Connection Green Film
(i) Fluid and Water Leakage

The following are definitions of the types/classes of leakage for determining the
status of fluid systems. Become familiar with them, and remember – WHEN IN
DOUBT, NOTIFY FIELD MAINTENANCE.
• Class l: Seepage of fluid indicated by wetness or discoloration that is not

great enough to form drops.
• Class ll: Leakage of fluid great enough to form drops but not enough to
cause drops to fall from item being checked/inspected.
• Class lll: Leakage of fluid great enough to form drops that fall from the item
being checked/inspected.
4-2
TM 9-2355-320-10
4-3. OPERATOR/CREW PREVENTATIVE MAINTENANCE CHECKS AND
SERVICES (PMCS)
NOTE
Prior to performing PMCS tasks, clean components as required.
Ensure the vehicle is on a hard, level surface prior to performing
PMCS.
(a) General Maintenance Procedures

This paragraph contains operator PMCS requirements of the vehicle. The
PMCS table contains checks and services necessary to ensure the vehicle is
ready for operation. Using the PMCS Table and Lubrication Instructions,
perform the maintenance at the specified intervals.
(b) Use of the PMCS Table

NOTE
Depending on mission profile of vehicle, some PMCS checks may not be
applicable.
1. Interval Column: This column describes when and how often checks are to
be made. Pay close attention to all CAUTIONS and WARNINGS. Checks
and services given in the tables are for normal operation. Extreme weather
conditions or periods of high use may dictate that the PMCS is performed
more often than is mentioned in the PMCS Table.
• B (Before): Perform BEFORE (B) PMCS just before operating the
vehicle and/or its components.
• D (During): Perform DURING (D) PMCS while the vehicle and/or its
components are in operation.
• A (After): Perform AFTER (A) PMCS right after operating the
vehicle and/or its components.
• W (Weekly): Perform WEEKLY (W) PMCS on a weekly basis.
• M (Monthly): Perform MONTHLY (M) PMCS on a monthly basis.
Perform all B and A PMCS tasks when performing monthly checks.
2. Item to be Inspected Procedure Column: This column lists specific items
to be checked and a brief description of the procedure by which the check is
to be performed.
• If a component does not pass PMCS inspection, troubleshoot it with
the instructions in this manual or notify Field Maintenance.
• Always perform PMCS in the same order.
• If a problem is found that is beyond your echelon of repair, report the
problem to Field Maintenance.
3. Not Mission Capable If Column: This column contains the criteria that
cause the equipment to be classified as not ready/not available because of
the inability to perform its primary mission. Notify Field Maintenance if the
severity of the problem is such that the vehicle cannot be operated.
4-3
TM 9-2355-320-10
(c) Armor PMCS
Armor PMCS is limited to inspection covered in the PMCS tables. These
include:
• Inspect condition of armor panels for damage and or corrosion.
• Ensure that all nuts and bolts are secure.
• First plate level may be replaced.
(d) Monthly PMCS Preparation

NOTE
Prior to performing monthly PMCS tasks, clean components as required.
Ensure vehicle is parked on a hard, level surface with the engine shut off
prior to performing PMCS.
These checks are to be made in the order listed, within designated
intervals.
4-4
TM 9-2355-320-10
Chapter 4 – PMCS MAINTENANCE INSTRUCTIONS
ITEM TO BE INSPECTED/PROCEDURE BEFORE OPERATING VEHICLE:

Not Mission Capable If:
Check for and have repaired, filled, or adjusted as needed.
Outside of Vehicle
a. Check exterior of vehicle for damage or missing items. Ensure all items are
properly secured.
b. Inspect all engine hatches and grills for damage and proper operation.
Tire Assembly
Tire or rim failure during tire inflation may cause personnel injury or death. Use tire cages.
Inadequate air pressure may lead to tire fire. Check and adjust tire pressures prior to operations.
Low tire air pressure may lead to tire failure. You can lose control of vehicle or rollover. Check tires
for proper inflation prior to operation.
Note
Crown repairs are limited to damage that will fit within a 1.575 inch (40 mm) circle. Cuts in rubber that do not
progress to the steel must be watched as the cut may split deeper into the rubber as the tire flexes.
a. Inspect tire and wheel assemblies and associated hardware for damage.
b. Check cold air pressure in tires. Air pressure should be appropriate for Any tire that cannot
conditions. maintain proper pressure
or is flat.
c. Inspect tires for wear, cuts, or damage. Any cut to the steel cable
of the radial casing or to
the steel belting in the
crown of the tire requires
tire to be removed from
service.
Ensure that valve stems are free of obstructions or are bent. If valve stem core is bent
or damaged.
4-5
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE BEFORE OPERATING

VEHICLE: Not Mission Capable
If:
Wheel Assembly
Wheel may be lost from vehicle resulting in loss of vehicle control/ rollover. Torque lug
nuts per TM.
Spilled fuel or oil can catch fire. Severe injury or death can occur. Wipe up spills
immediately.
a. Check for broken, loose, or missing wheel studs. More than two wheel
studs damaged, more
than two nuts missing
on any one wheel
assembly, or any
cracked or bent rim
impacts operation of
the wheel assembly.
b. Inspect wheel hubs for leaks. Check for white or discolored fluid. Any Class III leaks,
Check for presence of water in oil. insufficient oil, white or
discolored fluid, or
presence of water in oil.
4-6
TM 9-2355-320-10

If:
Fuel Tanks
Fuel is flammable and can explode. Keep fuel away from open flame and keep fire
extinguisher within easy reach when working with fuel. DO NOT work on fuel system
when engine is hot. Fuel can be ignited by hot engine. Smoking is prohibited while
working with fuel. Never use gasoline to clean parts. Failure to comply may result in
serious injury or death to personnel.
Do not fill fuel tank with engine running. Do not over fill fuel tank. Clean fuel spills
immediately. Ensure fuel nozzle is grounded to filler neck to prevent sparks. Failure to
comply may result in injury or death to personnel and damage to equipment.
Be alert at all times for the smell of fuel. Hot engines and components can ignite fuel. If
fuel smell is detected while operating vehicle, shut down vehicle immediately and
notify Field Maintenance. Failure to comply may result in damage to equipment, injury,
or death to personnel.
a. Lower fuel filler cover and ensure that fuel cap is installed.
b. Check filler neck screen for debris.
c. Check fuel filler cap rubber seal.
d. Check fuel tank for presence of fuel.
e. Open engine access cover/hood. Open primary fuel filter/separator If contaminants are
drain cock (1) and drain water into suitable container until clear present.
fuel comes out. Close drain cock and repeat for adjoining filter.
Check drained fuel for contaminants. Dispose of drained fluids
IAW local procedures. Close engine access cover/hood.
4-7
TM 9-2355-320-10

If:
Under Vehicle
Fuel is flammable and can explode. Keep fuel away from open flame and keep fire
extinguisher within easy reach when working with fuel. DO NOT work on fuel system
when engine is hot. Fuel can be ignited by hot engine. Smoking is prohibited while
working with fuel. Never use gasoline to clean parts. Failure to comply may result in
serious injury or death to personnel.
Do not fill fuel tank with engine running. Do not over fill fuel tank. Clean fuel spills
immediately. Ensure fuel nozzle is grounded to filler neck to prevent sparks. Failure to
comply may result in injury or death to personnel and damage to equipment.
Be alert at all times for the smell of fuel. Hot engines and components can ignite fuel. If
fuel smell is detected while operating vehicle, shut down vehicle immediately and
notify Field Maintenance. Failure to comply may result in damage to equipment, injury,
or death to personnel.
a. Inspect under vehicle for fluid leaks, such as oil, hydraulic fluid, Any leak of coolant or
coolant, fuel, etc. fuel. Any Class III oil
leak.
b. Visually inspect undercarriage, suspension, steering and drive train Any damage that will
for damage. hinder the vehicle
normal operations.
4-8
TM 9-2355-320-10

If:
Antennas
Personnel may be exposed to RF radiation. Shut off radios prior to working around or
touching the antennas.
a. Inspect antennas for damaged, loose, or missing hardware. Ensure Any damaged.
that antenna ball is present.
Power Distribution Center (PDC)
a. Check for obvious damage to PDC. Ensure that Circuit Breakers Any CB will not reset.
(CBs) are not tripped.
Driver/Commander Seat Controls
a. Adjust driver’s seat.
Driver/Commander Seat Belts
a. Check seat belts for correct mounting, damage, and proper Seat belt not in good
operation. working condition.
Missing hardware.
Severe cuts to belt.
Cam lock does not
latch.
Passenger Seat Belts
a. Check seat belts for correct mounting, damage, and proper Seat belt not in good
operation. working condition.
Missing hardware.
Severe cuts to belt.
Cam lock does not
latch.
b. Check seat mounting and suspension. Suspension
inoperative. Missing
hardware. Damaged
mounting.
4-9
TM 9-2355-320-10

If:
Top of Vehicle
NOTE
Use ladder behind driver’s door to access top of vehicle.
a. Visually inspect top of vehicle for damaged, loose or missing
hardware.
Doors:
a. Ensure that all doors open and latch securely. Check function of Latches and locks do
combat lock latches, manual release cables, all switches, and not engage.
external opening cable (external door assist).
Hatches
Note: This task is for the crew, not the operator.

a. Ensure that all hatches open and lock securely. Any hatch fails to
open, close, combat
lock, or maintain an
open position.
4-10
TM 9-2355-320-10

If:
Automatic Fire Suppression System (AFSS)
Fire suppression agent can irritate your throat and eyes. Prolonged exposure can make
you dizzy. After discharging fire suppression system, open hatch covers and turn on vent
fans, or get all personnel out of vehicle as soon as possible.
Engine fan can blow away fire suppression agent before fire is extinguished. Personnel
can get burned. Equipment can get damaged. Stop engine before you operate engine fire
suppression system.
a. Set Master Power switch to ON position. Inspect display on AFSS Self-test fails.
engine and crew controls for any LEDs that remain illuminated. Fault indicator blinks.
Illuminates for seven seconds at application of power.
4-11
TM 9-2355-320-10

If:
Mirrors
a. Inspect condition of mirrors and brackets. Adjust to ensure Broken mirror,
maximum field of view coverage. cracked, loose or
discolored.
Internal Lights
Check operation of all internal lights. Check operation of cab dome

lights (1). Check operation of crew dome light override (2). Press
EMER button (3) to turn off single light. Check operation of dimmer
switch (4). Toggle switch down for BO (green) and up for normal lights
(white).
Inverter
a. Check inverter light (1) illumination. Inverter is located behind the If “ok” light is not
commander’s seat. illuminated with vehicle
master power “ON”.
Vent Fans
a. Inspect vent fan for damage and air flow restrictions. Ensure that Vent fan does not
vent fans operate properly. operate.
4-12
TM 9-2355-320-10
If:
A/C System
a. Operate A/C system compressor switch fan controls. Compressor does not
engage. Fans do not
operate. Insufficient
cooling.
Personnel Heater
a. Operate personnel heater, HI/LO operation. Personnel heater fails
to start or operate
correctly.
Portable Fire Extinguisher Bottles
a. Check three hand-held portable fire extinguishers. Ensure that Hand-held fire
indicator gauge shows charged. Check mounting of bottles, seals, extinguisher missing,
and mounting brackets. Crew compartment and inside storage box bottle discharged, or
underneath door. seal is broken.
Extinguisher mounting
loose or damaged.
AFSS Troop Compartment and Engine Compartment Bottles
Fire suppression agent can irritate your throat and eyes. Prolonged exposure can make
you dizzy. After discharging fire suppression system, open hatch covers and turn on vent
fans, or get all personnel out of vehicle as soon as possible.
Flammable materials can burn. Do not store flammable materials in crew compartment.
Accidental discharge of fire bottles can injure you.
a. Read AFSS extinguisher cylinder pressure gauge (1) on two crew AFSS extinguisher
and one engine extinguisher cylinder. charge gauge shows
over/undercharge
(outside of green
range).
4-13
TM 9-2355-320-10

If:
Windows
a. Check windshield for damage that would impair operator’s vision. Windshield is cracked,
Keep clean inside and outside. broken, or discolored
(cloudy) sufficiently to
impair operator’s
vision.
b. Inspect inner surface of windows for complete breaks, The bond between
delamination, scratches, gouges, tape, decals, adhesives, or glass and frame is
blurred vision. separated from glass
or frame.
Any complete break on
inner surface of glass.
Any digs, gouges, or
scratches on inner
surface of glass. Any
complete break on
inner surface of glass.
c. Inspect outer surface of glass for a complete break. Any complete break on
the outer surface of
glass.
Windshield Washer Reservoir/Windshield Wipers
a. Check windshield washer fluid reservoir. Fill as required.
b. Check for missing or damaged wiper blades.
c. Check for normal windshield wiper operation.
4-14
TM 9-2355-320-10

If:
Batteries
Lead-acid gases can explode. Do not smoke, have open flames, or make sparks around a
battery, especially if caps are off. If a battery is gassing, it can explode and cause injury
to personnel. Ventilate when charging or using in a enclosed space. Wear safety goggles
and acid-proof gloves when battery cover must be removed or when adding electrolyte.
Avoid electrolyte contact with skin, eyes, or clothing. If battery electrolyte spills, take
immediate action to stop burning effects:
External: Immediately flush with cold running water to remove all acid.
Eyes: Flush with cold water for at least 15 minutes. Seek immediate medical attention.
Internal: Drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Seek immediate medical attention.
Clothing or Vehicle: Wash at once with cold water. Neutralize with baking soda or
household ammonia solution.
a. Check battery hold-downs for loose batteries. Check battery If any battery post is
connections for looseness and corrosion. Check that each clamp is damaged, loose, or
all the way down on the terminal post. If batteries move or seem corroded. Battery
loose, or if any clamp or connection is loose, tighten if loose. cracked or leaking.
4-15
TM 9-2355-320-10

If:
Engine Oil Level
Spilled fuel, lubricants, may lead to an engine compartment fire. Check for spills in the
engine compartment. Clean up spilled flammable materials.
Oily rags stored in engine compartment may cause fire. Do not store oily rags in the
engine compartment.
a. With vehicle parked on level ground, check oil level. Engine is overfilled with oil,
oil is discolored, or any
Class III leak.
Engine Coolant Level
Hot coolant can burn you. Do not remove radiator cap until coolant temperature
gauge reads in bottom one-quarter of green zone. Use heat protective mittens
to turn radiator cap. Turn cap slowly to release pressure.
a. Check coolant level in surge tank sight glass and coolant Any leak.
overflow reservoir. Surge tank should be full. Coolant overflow
reservoir should be above FULL COLD line. Check for leaks.
Fill as required.
b. Check radiator cap for damage or missing. Damaged or missing.
Power Steering Fluid Reservoir Level and Filter

a. Check fluid level on dipstick in hydraulic fluid reservoir. Fluid Any Class III leak.
level should be between the minimum and maximum levels on Contamination of fluid.
the dipstick. If fluid is low, add oil. Check lines and connectors
for leaks. Check for contamination.
Horn and Exterior Vehicle Lighting

a. Check horn operation. Turn light control through all positions Lighting not functioning.
and ensure that lights are functioning. Check all front, rear, and
side lights and spotlight for proper operation.
4-16
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE DURING OPERATING

If:
Engine Start-up
a. Start engine. Engine fails to start.
Engine
a. Listen for unusual noise, misfiring, and rough idling of engine. Any unusual noises,
Engine RPM must be between 700 and 1200 RPM at idle. misfiring, rough or
incorrect idling of engine,
or any engine faults
displayed on annunciator
panel.
Transmission Fluid Level
a. With engine running and at operating temperature, pull dipstick Transmission is over-filled
and check fluid level. Ensure that the indication is above ADD with fluid, fluid is
indication on dipstick. Fill as required. discolored, or puddle of
fluid is visible in engine
compartment.
Pneumatic System
Compressed air can injure you. Do not aim compressed air at yourself or other personnel.
Always wear goggles when working with compressed air. Do not use more pressure than
30 psi (207 kPa) with air nozzles.
Note:
Low pressure audible indicator should stop at 60 psi (414 kPa).
a. Allow 3.5 minutes for pneumatic pressure (1) to charge up to Pneumatic system fails to
120 psi, maximum operating pressure. Check operation of Lo reach 110-130 psi.
transfer case shift switch (2). Check that LED illuminates when
Hi-Lo transfer case shift switch is toggled to up position and
extinguishes when toggled to down position.
4-17
TM 9-2355-320-10

If:
Gauges and Indicators
a. Check all gauges for proper operation. Voltmeter 23-28 VDC Any gauge indicates
(1); Oil pressure gauges 5-87 psi (2); Air pressure gauge 60- abnormal operating range.
120 psi (3); Engine temperature gauge 125-250° F (4).
b. Engine fault indicator on annunciator panel (5) should illuminate Engine fault indicator
green. illuminates amber or red.
4-18
TM 9-2355-320-10

If:
Driver’s Instrument Panel
a. Check all instruments and gauges for proper operation. Readings are not within
normal operating range.
Brake System
Failure of air lines or air supply may cause vehicle brakes to lock up. Inspect air lines for
damage. Check air pressure gauge.
Control failures can cause vehicle to crash. Crash can kill or seriously injure personnel.
Check all controls for smooth operation. Do not drive vehicle if accelerator, steering, or
brake controls bind, or fail to return when released. Do not operate vehicle if engine does
not return to idle when accelerator pedal is released.
2
3
a. Pull parking brake knob (1) out and ensure that warning Parking brake indicator
indicator (2) is illuminated. Apply brakes and shift gear range fails to illuminate, parking
selector (3) in Neutral (N). Once air pressure gauge has brake fails to hold vehicle
reached 120 psi, press service brake three times and hold the in gear, or air gauge
third time for 1 minute. Observe air pressure gauge and listen indicates less than 60 psi
for audible air leaks. during brake test.
b. Ensure that brake system is functioning properly. Any brake failure detected.
4-19
TM 9-2355-320-10

If:
Transmission
1
a. Ensure that transmission shifts in all ranges. Check Any transmission faults
transmission or transmission temperature. If transmission icon displayed or damaged
on annunciator panel (2) illuminates, check transmission control.
selector screen (1) for transmission fault.
4-20
TM 9-2355-320-10

If:
Power Train
a. Be alert for unusual noises or vibrations from engine, Unusual noise or vibration
transmission, transfer case, differentials, drive shafts, axles, or is detected.
wheels.
Steering
Vehicle has high center of gravity. Vehicle may roll over. Make slow turns. Drive straight
up or down slopes when possible. Avoid traversing side slopes.
a. Ensure that vehicle tracks properly, and does not pull to the left Steering binds or loss of
or right or bind. steering function.
4-21
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE AFTER OPERATING

If:
Outside of Vehicle
a. Check exterior of vehicle for damage or missing items. Ensure
all items are properly secured.
b. Inspect all engine hatches and grills for damage and proper
operation.
Air Inlet Grill
a. Remove leaves and debris from air inlet grills.
Brake System
a. Listen for sounds of air leaks around front and rear service Air leak identified.
brake air tanks. Drain primary and secondary air tanks.
Undercarriage
Spilled fuel, lubricants may lead to an engine compartment fire. Check for spills in the
engine compartment. Clean up spilled flammable materials.
a. Inspect the undercarriage of the vehicle for fluid leakage, Not fully mission capable if
damaged, bent or loose steering, driveline or suspension any fuel leak or coolant
components and damaged air hoses. Check differentials for leak, Class III oil leak,
leaks. damaged steering,
suspension, or driveline
component, or leaking air
line.
4-22
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE AFTER OPERATING

If:
Wheel Hubs
Spilled fuel, lubricants may lead to a fire. Check for spills. Clean up spilled flammable
materials.
a. Inspect all wheel hubs for white or discolored fluid and leaks. Any Class III leaks, white
Check oil level from center oil fill plug. Oil level should be within or discolored fluid.
¼ inch of the oil fill hole.
AFSS Crew Compartment Sensors
a. Check all AFSS optical sensors for dirt or residue. Dirty lenses Dirt or residue cannot be
should be carefully swept with a dry soft lens tissue or a wet removed from optical
lens tissue followed by a dry tissue. sensors.
Armor
a. Inspect all roof and belly armor plates for dents, gouges, or Panels are severely
other damage. Check all armor plate fasteners for looseness combat damaged or
and missing mounting hardware. corroded.
4-23
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE WEEKLY OPERATING

If:
Exhaust System
Hot parts can burn you. Allow parts to cool before working on or near them. If necessary,
use heat protective gloves. Failure to comply may result in injury to personnel.
a. Check exhaust system for looseness, damage, or rust through Any cracked, broken, or
conditions on cold engine. missing components and
obvious exhaust leaks.
Turbocharger
a. Inspect oil and coolant lines/’fittings for signs of leaks or Any Class III leaks.
damage. Check mounting for loose bolts and air ducts clamp
for tightness. Check hoses for damage.
Fan, Fan Pulley and Belts
a. Check belt adjustment. Deflection should be no more than ½ Belts are loose.
inch (1.3 cm).
b. Check for cracked, frayed, or worn drive belts. Cracked, frayed, or worn
belts.
Generator
a. Check wiring connections, terminals, and mounting brackets for

looseness or damage.
Air Compressor
a. Inspect hoses, lines, and fittings for looseness or damage. Air lines damaged.
Radiator
a. Check for clogged or damaged fins and loose or damaged Any coolant leaks. Any
hoses to or from the radiator. obstructions in the
radiator.
Slave Connection
a. Inspect slave connection to insure cap is in place and

serviceable and receptacle is serviceable.
Heater/Vent/Defroster Controls
a. Check heat, vent, and defroster controls for proper operation.
A/C Condensor
a. Flush A/C condenser in each front fender with low pressure

water to remove dust and debris.
4-24
TM 9-2355-320-10
FIRE SUPPRESSION SYSTEM WEEKLY INSPECTION
Accidental discharge of the automatic fire suppression system can cause serious injury or
death to personnel. Ensure the automatic fire suppression system is deactivated before
conducting maintenance. Wear a face shield, ear protection, gloves, and protective clothing
during maintenance. Failure to comply may result in injury or death to personnel.
Preliminary Operations
The preliminary operations will be carried out when vehicle Master Power switch is set in the OFF
position and AFSS backup power supply circuit breaker pushed in (OFF).
Inspection Procedures
1. Make sure that optical detector lenses are clean. Dirty lenses should be carefully swept with
a dry soft lens tissue.
2. If necessary, a wet lens tissue with a cleaner could be used. Clean with dry lens tissue
afterwards.
3. Inspect all AFSS wiring connections for loose cables or damage at following locations:
• Optical sensors/Detection and Control Unit
• Backup Power Unit
• Extinguishers (engine and troop compartment bottles)
• Spot detectors (engine compartment)
• External emergency switches
4. Check condition of all AFSS hoses. Check for loose connections, torn lines, etc.
5. Inspect AFSS backup power supply circuit breaker operation. Make sure power is off when
breaker is in and on when breaker is out.
AFSS Built In Test (BIT)
If BIT fails, the FAULT indicators in both the ENGINE COMPARTMENT area and the CREW
COMPARTMENT area will light depending if detector fault or circuit control belongs to crew or
engine portion.
4-25
TM 9-2355-320-10
ITEM TO BE INSPECTED/PROCEDURE MONTHLY OPERATING

If:
Tow Pintle
a. Check for missing, loose, or damaged grease fitting or cotter pin. Pintle does not operate
or missing hardware.
Fuel Tank
a. Inspect fuel tanks for leaks or broken mountings. Any leaks or broken
mountings.
Fuel Lines and hoses
a. Check fuel lines and hoses for leakage and damage. Mare sure all Any leaks.
connections are secure.
Surge Tank
a. Check all hoses and connections for dry rot, damage, or leakage. Any leak.
Differential and Wheel Hubs
a. Visually inspect differentials for leakage. Any Class III leak.
b. Check fluid levels and fill if needed.
Side Door Assist
a. Check function of each safety sensor. Any sensor fails to stop
door mechanism when
activated.
b. Inspect actuator and hydraulic lines for leakage. Any Class II leak.
c. Check function of door assist pull cables. Does not deactivate
door assist.
d. Inspect mechanism for dirt and debris. Mechanism binds.
e. Inspect firewall connectors for proper/secure connection. Moisture or corrosion
on connection terminal.
Rear Suspension
a. Inspect for bent or cracked metal parts. Interference between
rubber and metal parts.
b. Inspect for oil and grease contamination of rubber springs. Spring diameter swells
1/4 in. beyond normal
position.
c. Inspect for cuts or splits in rubber springs. Cuts or splits over 3 in.
in length and over 1 in.
deep.
d. Inspect for bonding defects between rubber and metal surfaces of Separation over 1 1/2
bolter springs. in deep.
e. Inspect auxiliary spring height. Less than 3 1/2 in.
height.
f. Inspect rubber in suspension, equalizer beam and links for cracks, Missing, cracked, or
rot, or other damage. separated rubber
bushing.
4-26
TM 9-2355-320-10
CHAPTER 5 – MAINTENANCE INSTRUCTIONS
GENERAL
These instructions are provided as operator-level maintenance items. In the event the vehicle requires service
outside the scope of these instructions, do not attempt to service or repair problem without proper tools or
materials. Notify Field Maintenance of service requirement or problem.
WARNINGS, CAUTIONS, and NOTES

Always read and follow warnings, cautions, and notes provided in this section before, during, and after performing
operations.
• Warnings alert personnel of imminent danger of death, bodily harm, and possible vehicle damage if
personnel does not follow direction when performing an operation.
• Cautions alert personnel of imminent damage to vehicle or surroundings if personnel does not follow
direction when performing an operation.
• Notes provide personnel with information pertinent and helpful to completing an operation.
5-1/5-2 blank
TM 9-2355-320-10
CHAPTER 5 – MAINTENANCE INSTRUCTIONS - CONTINUED
JACKING VEHICLE
WARNING
Never work under a vehicle that is only supported by a jack. Ensure the vehicle is on a hard,
level surface and jack stands are available and securely in place to support vehicle. Failure to
comply may result in injury or death to personnel.
1. Park vehicle on suitable firm and level ground.
2. Apply parking brake.
3. If necessary, engage transfer case AWD selection to lock wheels.
4. Put transmission in neutral (N).
5. Put ignition switch in OFF position.
6. Place Master Power switch in OFF position.
7. Place wheel chocks in front of and behind one rear wheel not being removed.
8. Remove jack and jacking plates from vehicle stowage location.
NOTE
Rotate neck of jack counterclockwise for additional jacking height.
9. Place jack (1) and jacking plates (3) in correct position under vehicle jacking location.
a. To raise front axle, place jack (1) and jacking plates (3) under spring perch (2), inboard of correct
wheel.
b. To raise intermediate or rear axle, place jack (1) under rear suspension equalizer beam (4) at correct
wheel.
10. Use handle (5) to raise jack to required height. Install suitable jack stand to support vehicle.
5 1
5
11. Make sure area is clear of personnel and objects, remove jack stands, and lower jack when finished.
12. Return jack and jacking plates to stowage area.
13. Remove wheel chocks.
5-2
TM 9-2355-320-10
REPLACE FRONT WHEEL/TIRE
REMOVAL
WARNING
Ensure proper lifting procedures are followed when removing or installing heavy components.
Use the aid of an assistant(s) or using lifting device as necessary. Failure to comply may result
in severe injury or death to personnel and damage to equipment.
NOTE
Intermediate and rear wheels must be done at Field level maintenance.
1. Raise vehicle with jack and position trestle under vehicle.

2. Remove ten lug nuts (2) from wheel studs (3).
3. Remove wheel/tire assembly (1) from vehicle.
1 2 3
5-3
TM 9-2355-320-10
REPLACE FRONT WHEEL/TIRE - CONTINUED
INSTALLATION
1. Position wheel/tire assembly (1) on vehicle.
WARNING
Anti-corrosion compound is toxic. Use only in a well-ventilated area. Use NIOSH/MSHA-

approved respirator with dual organic vapor/mist and particulate cartridge. Wear chemical
safety goggles and full face shield when using. Avoid contact with skin and wear rubber or
plastic gloves. In case of contact, remove contaminated clothing and immediately wash area
with soap and water. If eyes are contaminated, flush with large amounts of water for at least 15
minutes and get immediate medical attention. If swallowed, DO NOT INDUCE VOMITING;
contact a physician immediately. Failure to comply may result in serious injury or death to
personnel.
2. Apply anti-corrosion compound to ten wheel studs (3).

3. Install ten lug nuts (2) on wheel studs (3).
4. Tighten ten lug nuts (2) between 350 to 400 lb-ft (474 to 542 N•m) in a crossing pattern.
5. Remove trestle from vehicle and lower vehicle to ground.
1 2 3
5-4
TM 9-2355-320-10
REPLACE FUEL FILLER NECK STRAINER
REMOVAL
WARNING
engine compartment.
1. Remove fuel filler cap (1) from fuel filler neck (2).
2. Remove three crosshead screws (1) that attach the strainer (2) to the filler neck (3). Lift strainer out.
5-5
TM 9-2355-320-10
REPLACE FUEL FILLER NECK STRAINER - CONTINUED
INSTALLATION
WARNING
engine compartment.
6. Install strainer (2) into filler neck (3).

7. Attach strainer (2) to filler neck with three crosshead screws (1). Do not over-tighten screws.
8. Install fuel filler cap (4) onto fuel filler neck (5).
5-6
TM 9-2355-320-10
REPLACE AIR CLEANER FILTER
REMOVAL
WARNING
NBC agents remain in air filter media and can kill or seriously injure personnel. If NBC
exposure is suspected, all air filter media should be handled by personnel wearing protective
equipment. Consult your unit NBC officer or NBC NCO for appropriate handling and disposal
instructions.
NOTE
Replace air filter when air intake restriction gauge on vehicle dash reads 22 in. H2O (5.5 kPa) or
higher.
1. Turn handle (2) counterclockwise to open air box access door (1) on passenger’s side of vehicle.
1 2
2. Release clamp (4) that holds retainer bar (6) against air filter element (3).
3. Pull retainer bar (6) away from air filter element (3) and remove element from air box.
4. Inspect seal (1), pre-cleaner (2), and inside of air box (5) for damage, obstructions, or debris. Clean inside
of air box or call Field Maintenance if damage is found.
2
1
3
6
5
5-7
TM 9-2355-320-10
REPLACE AIR CLEANER FILTER - CONTINUED
INSTALLATION
1. Install air filter element (1) into air box.
2. Position retainer bar (3) over air filter element (1).
3. Engage clamp (2) with retainer bar (3) and lock into place. Adjust clamp length if necessary. Clamping
force should be enough that clamp will not release. Do not over-tighten.
4. Close air box access door (1) and lock by turning handle (2) clockwise. Make sure access door is secure.
1 2
5-8
TM 9-2355-320-10
REPLACE AIR CLEANER FILTER - CONTINUED
INSTALLATION - CONTINUED
5. Press reset button (1) on air filter restriction gauge (2), located on driver’s side vehicle dash panel.
6. Start vehicle engine and verify restriction gauge (2) does not indicate excessive air intake restriction.
Notify Field Maintenance if necessary.
REPLACE HULL DRAIN PLUG

NOTE
Hull drain plug is located directly below rear door. Ensure rear door is locked to
prevent injury from the door being opened. Esnure vehicle is parked on a level spot
or front of vehicle is pointed uphill.
Use an adjustable wrench to remove and install drain plug (1). Allow ample time for water and other liquids to
drain from vehicle when removed. When all liquids have been drained, reinstall drain plug.
5-9
TM 9-2355-320-10
DRAIN AIR TANKS

WARNING
Air system operates at 120 psi (828 kPa). This pressure will damage eyes and cause bodily
injury. Always drain air tanks before working on any part of air system. Do not attempt to
charge system until work is complete. Failure to comply may result in severe injury or death to
personnel.
Do not operate vehicle with low air pressure. Vehicle service brakes will not work. Ensure air
pressure gauge remains in normal operating range. Rapid, repeated operation of the brakes
may deplete compressed air reservoirs. Loss of air pressure will cause the emergency brakes
to engage. Failure to comply may result in injury to personnel or damage to equipment.
NOTE
Vehicle pneumatic system has three air tanks. Procedure to drain all tanks is same.
Grasp air tank lanyard (2) and pull to release air from drain valve (1). Make sure drain valve returns to closed
position when released.
5-10
TM 9-2355-320-10
REAR SPRING BRAKE CAGING
WARNING
Wear appropriate eye protection when working under vehicle due to the possibility of
falling debris. Failure to comply may result in injury to personnel.
NOTE
To cage brakes, apply caging procedure to both front and rear spring brake
chambers on each wheel of rear and intermediate axles.
Lock caging bolt (1) in place by turning caging bolt counterclockwise until bolt reaches stop.
5-11
TM 9-2355-320-10
REAR SPRING BRAKE UNCAGING
WARNING
Wear appropriate eye protection when working under vehicle due to the possibility of
falling debris. Failure to comply may result in injury to personnel.
NOTE
To uncage brakes, apply uncaging procedure to both front and rear spring brake
chambers on each wheel of rear and intermediate axles.
Uncage brakes by turning caging bolt (1) clockwise until bolt reaches stop.
5-12
TM 9-2355-320-10
LUBRICATION INSTRUCTIONS
INTRODUCTION
New vehicles are lubricated before they are delivered. After the vehicle is placed in operation, regular
lubrication intervals, based on the type of service and road conditions, should be established.
The interval between lubrication periods, oil changes, etc., depends entirely upon operating conditions. The
loads carried, the vehicle speed, the road, and the weather conditions all contribute to the frequency of
lubrication periods.
In some types of operation, and where operating conditions are extremely severe (such as in deep water,
mud, or unusually dusty conditions), the vehicle may require lubrication after every twenty-four (24) hours of
operation.
The lubrication specifications refer only to the viscosity (SAE) and type to be applied. The viscosity numbers
have been adopted by the Society of Automotive Engineers to classify lubricants according to viscosity and
do not cover any other properties.
Unless otherwise specified, never add lubricant unless it is the same grade as that which is already in use. If
the grade is unknown or not available, drain, flush, and refill with new lubricant.
LUBRICATION INTERVALS
Lubrication intervals are provided for normal highway, city, and severe service. In all applications the actual
interval should be performed at whatever interval occurs first, whether it is months, miles (kilometers), hours
of operation, or passage of time (months).
Table 1. Lubrication Interval.
ENGINE OIL TRANSMISSION 315-M1/T-CASE AXLES/DIFFERENTIALS
9,000 miles or 500 hours 12,000 miles Initial check 2,000 miles First oil change 100 hours
severe operations or 2,500 miles.
6 months First oil change 3,000
15,000 miles or 500 hours miles Lubricant level check
500 hrs
normal operations every 250 hours or 5,000
Scheduled change at
miles.
50,000 miles
Oil change interval is
every 25,000 miles.
15W/40 OIL 15W/40 OIL 75W/90 Synthetic gear oil 80W/90 Gear oil
or 15W/40 OIL
AXLE WHEEL HUBS ENGINE COOLANT LUBE POINTS AIR FILTER
First oil change 100 hours Coolant filter replace See Table 2. Lubrication Change every 6 months
or 2,500 miles. 18,000 miles, 500 hours, Points. or sooner as operating
or 6 months. conditions warrant.
Lubricant Level check
every 250 hours or 5,000 72,000 miles, 2,000
miles. Oil change interval hours, or 2 years fluid
is every 25,000 miles. replacement.
80W/90 Gear Oil Low Silicate Propylene
Glycol. Or Ethylene
Glycol.
5-13
TM 9-2355-320-10
Table 2. Lubrication Points.
Lube Pts Location Normal Op. Severe Op. Type POL
Left and right side (above

Draglink Arm 1 Month or 1,000 miles GAA
front axle)
Steering Control Left and right side (above

1 Month or 1,000 miles GAA
Arm front axle)
Left and right side (on axle

Tie-rod End 1 Month or 1,000 miles GAA
lower steering arm)
Left and right side (one
Front Leaf Spring
forward of front axle, two 1 Month or 1,000 miles GAA
Shackle
behind front axle)
Left side hinge (upper and
Driver’s Door 1 Month or 1,000 miles GAA
lower)
Right side hinge (upper and

Passenger Door 1 Month or 1,000 miles GAA
lower)
Four on top of vehicle
Hatch Locking
(located on end of hatch 1 Month or 1,000 miles GAA
Pins
torsion bar)
Rear of vehicle (upper and
Cargo Door 1 Month or 1,000 miles GAA
lower)
Rear of vehicle (swivel and

Tow Pintle 2 Month or 2,000 miles GAA
lock)
Driveshaft One fitting each driveshaft 2 Month or 2,000 miles GAA
Driveshaft
One fitting on each U-Joint 2 Month or 2,000 miles GAA
U-Joints
5-14
TM 9-2355-320-10
CHAPTER 6 – SUPPORTING INFORMATION
6-1. BII (BASIC ISSUE ITEMS)
a. Introduction
This appendix lists Basic Issue Items (BII) to help you inventory the items for safe and efficient operation
of the equipment.
b. General
These essential items are required to place the vehicle in operation, operate it, and to do emergency
repairs. Although shipped separately packaged, BII must be with the vehicle during operation and when it
is transferred between property accounts. Illustrations are furnished to help you find and identify the
items.
Basic Issue Items (BII)

National Stock Unit of
Item Nomenclature QTY
Number Issue
Adapter, Grease Gun (5855) 4930-00-204-2550 EA 1
Adapter, Socket Wheel Wrench, ¾-1 ½ (TR55) 5120-01-298-0317 EA 1
Bag, Assembly, Pamphlet (11676920) 2540-00-670-2459 EA 1
Bag, Tool Satchel (11655979) 5140-00-473-6256 EA 1
Bar, Pin., 26 in. (15840) 5120-00-224-1372 EA 1
Binder, Loose Leaf, 3 Ring, Green (11677003) 7510-00-889-3494 EA 1
Brush, Wire Scratch (20010) 7920-00-269-1259 EA 1
Can, Fuel, Military, Tan (MIL-C-58109) 7240-01-337-5268 EA 2

Can, Water, Military, Plastic, 5 gal., Tan (MIL-C-
EA 2
43613) 7240-00-089-3827
Chock, Wheel (A52475-2) 2540-01-500-6119 EA 2
Coupling Assembly, Quick-disconnect (Emergency)
EA 1
(10512396) 4730-01-171-2275
Coupling Assembly, Quick-disconnect (Service)
EA 1
(10512399) 4730-01-171-2276
Crowbar, Pin. Point, 59 - 62 in.es (12-924) 5120-00-224-1390 EA 1
Extension, Socket Wrench, 10 in. long, ½ in. Dr (12-
EA 1
924) 5120-00-227-8074
Extension, Socket Wrench, 5 in. long, ½ Dr (SXK5) 5120-01-335-1050 EA 1
Extinguisher, Fire, Portable, CO2, 2.5 lb (A52471-1-S) 4210-01-388-7854 EA 2
6-1
TM 9-2355-320-10
CHAPTER 6 – SUPPORTING INFORMATION - CONTINUED
Basic Issue Items (BII) - Continued

Unit of
Item Nomenclature National Stock Number QTY
Issue
First Aid Kit, General Purpose (SC C-6545-IL Vol 2) 6545-00-922-1200 EA 1
Fitting, Lubrication, Straight (1199N1860) 4730-00-050-4208 EA 1
Flashlight MX 991U (N47-IB) 6230-00-264-8261 EA 2
Floodlight, Handheld w/25 ft Cord (CD-KN-6MF-25) NA EA 1
Folder, Equipment Record, 2.5 in. x 8 in. x 10 in. (MIL-F-
EA 1
43986) 7510-01-065-0166
Funnel, Steel, Flex Mount (495) 7240-00-559-7364 EA 1
Gage, tire pressure w/hose (11677140-5-MODLB) 4910-01-038-2820 EA 1
Hammer, Hand, Machinist's Ball Peen, 2 lb (4532) 5120-00-061-8546 EA 1
Hammer, Hand, Sledge, Double-Faced, 10 lb (11206) 5120-00-243-2957 EA 1
Handle, Socket Wrench, 1/2 in. (1441502) 5120-00-230-6385 EA 1
Jack, Hydraulic, Hand, 20 ton (N76520) 5120-01-351-2074 EA 1
Key Set, Socket Head (AWM140DK) 5120-01-335-1508 EA 1
Litter, Folding, 91.60 in. (100047) 6530-01-380-7309 EA 1
Lubricating Gun, Hand (1142) 4930-00-253-2478 EA 1
Max Tool Kit, Combination Tool, Hand (Optional) (585) 5120-01-416-8568 EA 1
Padlock (AA59486-2AS10S0E2) 5340-01-408-8452 BX 1
Panel Marker Signal, Ground to Air, Red/Yellow (8345-
EA 2
00-174-6865) 8345-00-174-6865
Pliers, Combination, Slip Joint, 8 in. long (10510983) 5120-00-223-7397 EA 1
Pliers, Lineman Side Cutting, 8 in. (201) 5120-00-239-8251 EA 1
Screwdriver, Cross Tip, #2, 4 in. long (10510985) 5120-00-234-8913 EA 1
Screwdriver, Cross Tip, #3, 6 in. long (314) 5120-00-234-8912 EA 1
Screwdriver, Flat Tip, #2, 6 in. long (66-110) 5120-00-293-3309 EA 1
Socket, Socket Wrench, 1/2 in. Dr, 1/2 in., 6 pt. (9-
EA 1
44055) 5120-01-398-7937
Socket, Socket Wrench, 1/2 in. Dr, 10 mm, 6 pt. (53-
EA 1
9110) 5120-01-349-4547
EA 1
44255) 5120-01-398-8033
Socket, Socket Wrench, 1/2 in. Dr, 14 mm, 6 pt. 5120-01-398-8035 EA 1
Socket, Socket Wrench, 1/2 in. Dr, 15/16 in., (7330H) 5130-00-714-0600 EA 1
Socket, Socket Wrench, 1/2 in. Dr, 16 mm, 6 pt.
EA 1
(TWM16) 5120-01-348-9035
6-2
TM 9-2355-320-10
Basic Issue Items (BII) - Continued

Unit of
Item Nomenclature National Stock Number QTY
Issue
Socket, Socket Wrench, 1/2 in. Dr, 18 mm, 6 pt.
EA 1
(TWM18) 5120-01-348-9037
EA 1
44259) 5120-01-398-7919
EA 1
124) 5120-00-189-7985
Socket, Socket Wrench, 1/2 in. Dr, 5/8 in., 12 pt.
EA 1
(533120) 5120-00-189-7946
Socket, Socket Wrench, ½ in. Dr, 7/16 in., 12 pt.
EA 1
(B107.1) 5120-00-237-0984
EA 1
74563) 5120-00-189-7934
Socket, Socket Wrench, 1/2 in. Dr, 9/16 in., 12 pt.
EA 1
(147102) 5120-00-189-7932
Socket, Socket Wrench, ¾ in. Dr, 15/16 in., 12 pt. (SP
EA 1
5530) 5120-01-399-9685
Socket, Socket Wrench, ¾ in. Dr, 1 1/8 in., 12 pt. (SP
EA 1
5536) 5120-01-399-9683
Socket, Socket Wrench, ¾ in. Dr, 1 ½ in., 12 pt. (SP
EA 1
5548) 5120-01-399-9686
Spout, Can, Flexible w/Filter Scrn, 2 1/2 in. OD, 16 in. lg.
EA 1
(11677020) 7240-00-177-6154
Support Plate, Jacking (10556067) 5340-21-914-1589 EA 2
Technical Manual, Operators -10 (TM 9-2355-108-10) NA 1
Tow Harness, Electrical (4299976) NA EA 1
Warning Device Kit, Highway (11669000) 9905-00-148-9546 EA 1
Wrench, Adjustable, 12 in. (1165578-5) 5120-00-264-3796 EA 1
Wrench, Adjustable, 8 in. (11655778-3) 5120-00-240-5328 EA 1
Wrench, Lug Nut- Extension, Socket Wrench, 8 in., ¾ in.
EA 1
Drive (FAC01016) 5120-00-243-7328
Wrench, Lug Nut- Handle, Socket Wrench, 19.5 in.
EA 1
Sliding Tee, ¾ in. Dr (5029209-108-101) 5120-00-709-4072
Wrench, Lug Nut- Socket, Socket Wrench, 33 mm
EA 1
(07533M) 5130-01-400-0196
Wrench, Plier (10WR) 5120-00-494-1911 EA 1
Wrench, Wheel Stud Nut, 1 ½ in. (12933) 5120-00-378-4411 EA 1
6-3
TM 9-2355-320-10
6-2. EXPENDABLE AND DURABLE ITEMS LIST
INTRODUCTION
Scope
This work package lists all expendable and durable items that you will need to operate and maintain the MRAP
RG33L Plus. This list is for information only and is not authority to requisition the listed items. These items are
authorized to you by CTA 50-970 Expendable/Durable Items (except Medical, Class V Repair Parts, and Heraldic
Items), or CTA 8-100, Army Medical Department Expendable/Durable Items.
Explanations of Columns in the Expendable/Durable Items List
Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative
instructions to identify the item, e.g., "Use hydraulic fluid (Item 5, WP 0100 00).”
Column (2) - Level. This column includes the lowest level of maintenance that requires the listed item (C =
Operator/Crew).
Column (3) - National Stock Number. This is the NSN assigned to the item which you can use to requisition it.
Column (4) - Description, Number (P/N), and Commercial and Government Entity Code (CAGEC). This column
provides the other information you need to identify the item.
Column (5) - Unit of Issue (U/I). This code shows the smallest quantity of an item that can be requisitioned and
issued.
6-4
TM 9-2355-320-10
EXPENDABLE AND DURABLE ITEMS LIST - Continued
Table 1. Expendable and Durable Items List
(1) (2) (3) (4) (5)
Item National Description, Part Number,

Number Level Stock Number CAGEC U/I
1 C Antifreeze, 60/40 mix DR

A-A-52624 (58536)
6850-01-464-9096 55 gal
2 C Antifreeze, Multi-Engine
A-A-52624 (81349)
5 gal CO
6850-01-464-9152 50 gal Recycled 100% DR
3 C Cleaning Compound, BX
Windshield, O-C-1901
(81348)
6850-00-926-2275 12 ea, 16 oz. pkg
4 C 9150-00-664-0047 Damping Fluid, W-D-10 LB

(81348)
5 C 9140-00-286-5294 Diesel Fuel grade DF-2, GL

ASTM D 975 (81346)
9140-00-286-5295 5 gal CN
9140-00-286-5297 55 gal DR
6 C 9140-00-286-5286 Diesel Fuel grade DF-1, GL

ASTM D 975 (81346)
9140-00-286-5288 55 gal DR
9140-00-286-5287 5 gal CN
6-5
TM 9-2355-320-10
Table 1. Expendable and Durable Items List - Continued
(1) (2) (3) (4) (5)
Item National Stock Description, Part Number,

Number Level Number CAGEC U/I
7 C 8415-00-266-8675 Gloves, Rubber, (MIL-DTL- PR

32066)
(81349)
8 C 4240-00-052-3776 Goggles, Industrial PR

(ANSIZ87.1) (80204)
9 C Grease, Automated and

Artillery (GAA),
MIL-G-10924 (81349)
9140-01-197-7688 2.25 oz TU
9150-01-197-7693 14 oz CA
9150-01-197-7692 35 lb CN
10 C 9150-00-252-6383 Hydraulic Fluid, Petroleum QT

Base, RYCO 756 (07950)
9150-00-223-4134 1 gal GL
9150-00-082-7524 10 gal DR
9150-00-265-9408 55 gal DR
10.1 C 9150-00-935-9808 Hydraulic Fluid, Petroleum GL

Base, RYCO 783 (07950)
1 gal
10.2 C 9150-00-265-9408 Hydraulic Fluid A MIL-H- GL

5606A (81349)
55 gal
6-6
TM 9-2355-320-10
Table 1. Expendable and Durable Items List - Continued
(1) (2) (3) (4) (5)

11 C Kerosene, ASTM D3699
12 C Oil, Lubricating, Gear,

GO 75W, M2105-1-75W
(81349)
9150-01-035-5390 1 qt QT
9150-01-035-5391 5 gal GL
13 C Oil, Lubricating, Gear,

GO 80W-90, MIL-PRF-
2105
(81349)
9150-01-035-5392 1 qt QT
9150-01-035-5393 5 gal CN
9150-01-035-5394 55 gal DR
14 C Oil, Lubricating,
OE/HDO 10, MIL-PRF-
2104
(81349) GL
9150-01-496-1946 5 gal CN
9150-01-496-1939 55 gal DR
15 C 9150-01-496-1957 Oil, Lubricating, QT

OE/HDO 10W, MILL2104
(81349)
6-7
TM 9-2355-320-10
Table 1. Expendable and Durable Items List – Continued
(1) (2) (3) (4)

16 C 9150-01-518-9477 Oil, Lubricating, QT

OE/HDO 15W-40, MIL-M-
2104 (81349)
9150-01-421-1424 5 gal CN
9150-01-421-1432 55 gal DR
17 C Oil, Lubricating, OE/HDO

30
(SAE 30), MIL-L-2104
(81349)
9150-01-433-7974 5 gal CN
9150-01-433-7986 55 gal DR
18 C 9150-01-433-7970 Oil, Lubricating, OE/HDO CN

40, MIL-L-2104 (81349)
5 gal
19 C 9150-00-402-2372 Oil, Lubricating, OEA, CN

9150-00-491-7197 MIL-L-46167 (81349) DR
5 gal
55 gal
6-8
TM 9-2355-320-10
(1) (2) (3) (4) (5)

20 C 9140-00-247-4364 Fuel Oil, Burner DR

ASTM-D-396 (81346)
21 C 7920-00-205-1711 Rag, Wiping BE
22 C 7930-00-634-3935 Soap, Laundry DR
23 C
6850-00-281-1985 Dry Cleaning Solvent GL

6850-00-664-5685 QT
24 C
25 C 9140-00-286-5286 Diesel Fuel GL

9140-00-286-5288 ASTM-D-975 (81346) DF-1 DR
9140-00-286-5289 DR
6-9
TM 9-2355-320-10
(1) (2) (3) (4) (5)

26 C Turbine fuel, aviation,

kerosene type grade JP-8
MILT-
83133 (81349)
9140-00-286-5294 GL
9140-00-286-5296 55 gal DR
9140-00-286-5297 55 gal DR
27 C Turbine fuel, grade JP-5,

MILT- 5624 (81349)
9130-01-305-5596 DR
9130-01-250-6353 55 gal DR
28 C Turbine fuel, MIL-F-16884

(81349)
9140-00-273-2377 GL
9140-00-255-7764 5 gal CN
55 gal DR
29 C 9130-01-429-4563 Turbine fuel, aviation, GL

kerosene type grade JP-8,
MIL-T-83133 (81349)
6-10
Use Part II (reverse) for Repair Date
Parts and Special Tools Lists
RECOMMENDED CHANGES TO PUBLICATIONS (RPSTL) and Supply
AND BLANK FORMS Catalogs/Supply Manuals SC/SM).
For use of this form, see AR 25-30; the proponent agency is

ODISC4.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (include ZIP code)
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Operator Manual Commercial

TM 9-2355-320-10 Off-The-Shelf (COTS) for MRAP RG33L
Plus 2355-01-562-6675
ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO.
0052 00-4 Inspection Step 1 WP reference should be (WP 0003 00)
*Reference to line numbers within the paragraph or subparagraph.

TYPED, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
USAPPC V3.0
TO: (Forward direct to addressee FROM: (Activity and location) (Include Date
listed in publication) Zip Code)
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE Operator Manual Commercial Off-The-Shelf
TM 9-2355-320-10 (COTS) for MRAP RG33L Plus 2355-01-562-6675
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM TOTAL NO.
NO. NO. NO. NUMBER NO. NO. NO. OF MAJOR RECOMMENDED ACTION
ITEMS
SUPPORTED
PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed).

EXTENSION
USAPPC V3.00

ODISC4.

Plus 2355-01-562-6675
NO.

EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
USAPPC V3.00
ITEMS
SUPPORTED

EXTENSION
USAPPC V3.00

ODISC4.

Plus 2355-01-562-6675
NO.

EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC
V3.00
ITEMS
SUPPORTED

EXTENSION
USAPPC V3.00

ODISC4.

Plus 2355-01-562-6675
NO.

EXTENSION
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC
V3.00
ITEMS
SUPPORTED

EXTENSION
USAPPC V3.00
THE METRIC SYSTEM AND EQUIVALENTS
LINEAR MEASURE SQUARE MEASURE
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq. Centimeter = 100 Sq. Millimeters = 0.155 Sq. Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq. Meter = 10,000 Sq. Centimeters = 10.76 Sq. Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq. Kilometer = 1,000 Sq. Meters = 0.386 Sq. Miles
WEIGHTS CUBIC MEASURE

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu. Centimeter = 1,000,000 Cu. Millimeters = 0.06 Cu. Inches
1 Kilogram = 1000 Grams = 2.2 Lb. 1 Cu. Meter = 1,000,000 Cu. Centimeters = 35.31 Cu. Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
LIQUID MEASURE TEMPERATURE
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 5/9 (˚F - 32) = ˚C
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 212˚ Fahrenheit is equivalent to 100˚ Celsius
90˚ Fahrenheit is equivalent to 32.2˚ Celsius
32˚ Fahrenheit is equivalent to 0˚ Celsius
(9/5 x ˚C) + 32 = ˚F
APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BY
Inches Centimeters 2.540
Feet Meters 0.305
Yards Meters 0.914
Miles Kilometers 1.609
Square Inches Square Centimeters 6.451
Square Feet Square Meters 0.093
Square Yards Square Meters 0.836
Square Miles Square Kilometers 2.590
Acres Square Hectometers 0.405
Cubic Feet Cubic Meters 0.028
Cubic Yards Cubic Meters 0.765
Fluid Ounces Milliliters 29.573
Pints Liters 0.473
Quarts Liters 0.946
Gallons Liters 3.785
Ounces Grams 28.349
Pounds Kilograms 0.454
Short Tons Metric Tons 0.907
Pound-Feet Newton-Meters 1.356
Pounds per Square Inch Kilopascals 6.895
Miles per Gallon Kilometers per Liter 0.425
Miles per Hour Kilometers per Hour 1.609
TO CHANGE TO MULTIPLY BY
Centimeters Inches 0.394
Meters Feet 3.280
Meters Yards 1.094
Kilometers Miles 0.621
Square Centimeters Square Inches 0.155
Square Meters Square Feet 10.764
Square Meters Square Yards 1.196
Square Kilometers Square Miles 0.386
Square Hectometers Acres 2.471
Cubic Meters Cubic Feet 35.315
Cubic Meters Cubic Yards 1.308
Milliliters Fluid Ounces 0.034
Liters Pints 2.113
Liters Quarts 1.057
Liters Gallons 0.264
Grams Ounces 0.035
Kilograms Pounds 2.205
Metric Tons Short Tons 1.102
Newton-Meters Pound-Feet 0.738
Kilopascals Pounds per Square Inch 0.145
Kilometers per Liter Miles per Gallon 2.354
Kilometers per Hour Miles per Hour 0.621
PIN: 000000-000

TM - 9 - 2355 - 320 - 10 - RG33L Plus

Enviado por

Dados do documento

Descrição original:

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

TM - 9 - 2355 - 320 - 10 - RG33L Plus

Enviado por

Direitos autorais:

Formatos disponíveis

TM 9-2355-320-10

MRAP RG33L PLUS

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

MANUFACTURED BY BAE SYSTEMS LAND AND ARMAMENTS GROUND SYSTEMS

WARNINGS, CAUTIONS and NOTES

Carbon monoxide occurs in the exhaust of fuel-burning heaters and internal-combustion

THE BEST DEFENSE AGAINST CARBON MONOXIDE

1. DO NOT operate heater or engine of vehicle in an enclosed area unless it is ADEQUATELY

DO NOT use CARC paint without adequate ventilation.

NEVER weld or cut CARC coated materials.

Brakes can catch fire. Keep brakes clean of flammable materials.

Do not make seat adjustments while driving. You can crash.

Anti-corrosion compound is toxic. Use only in a well-ventilated area. Use NIOSH/MSHA-

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

LIST OF ABBREVIATIONS - CONTINUED

LIST OF ABBREVIATIONS - CONTINUED

WATER AND FUEL STORAGE BOX

MRAP RG33L Plus Category II Specification

MRAP RG33L Plus Category II Specification - Continued

Driver’s and Commander’s Seat

The powerpack consists of the following major components:

Transfer Gear Box

6 x 6 Mode with Differential Loc (Deep Snow, Sand & Mud)

DAY TANK 3.9 GAL. (14.7 L)

Day Tank Overflow

Check Fuel Supply Shut off

Reservoirs (Supply Tank, Secondary Service Tank, Primary Service Tank)

Low Pressure Switch

Air Conditioning System

Heater Installation Left Rear Corner Heater Installation - Exterior View

Heater Fuel Line Routing

The general layout is shown below:

Following is the AFSS Control Box located on dash.

AFSS Control Box

3. Audible alarms will sound for the following reasons:

Rear and Side Door Assist

Applique Armor Effector Panels

1. Operate parking brake control valve (Yellow):

c. Pull out parking brake control (2).

1. Ensure parking brake (4) has been applied (pulled out).

1. Put the transmission in N (Neutral).

1. Release parking brake.

a. Press operator brake pedal to steady vehicle.

1. Apply service brake to stop vehicle (if required).

6. Move Master Power switch (1) to OFF position.

From outside the vehicle:

From outside the vehicle:

Do not make seat adjustments while driving. You can crash.

ADJUST SEAT BACK

Do not make seat adjustments while driving. You can crash.

1. To select All Wheel Drive (AWD) position:

• Both the rear and front differentials can be locked.

6. Engage T-CASE Neutral:

OPERATE WINDSHIELD WIPER

Power for interior lighting is controlled by the Master Power switch.

Engine and personnel heater exhaust fumes are very toxic.

The heater can be started with the HI/LO switch in HI or LO position.

Heater life will be extended if operated in LO temperature setting.

Table 1. Operational Modes (displayed on personnel heater).

HEATER OPERATION FAULTS

Table 2. WARNING Faults.

Table 3. Shutdown Faults.