This manual is cow& to 11 Auguut 1066 *TM 9-8012/TO WAS-241 I HXiNICAL DEPARTMENTS OF THE ARMY AND No. 9-6012 THE AIR FORCE TBCHNICAL OaDpir No. 96A6%41 26, D. C., I% Kay 1966 h-ton 4 X 4 UTILITY TRUCK CHAPrER 1. Section I. II. c!h_ 2. Section I. II. III. IV. V. CHAPTER 3. Section I. II. III. xv. V. VI. VII. VIII. INTRODUCTIOti ParcrgroPb Pwe General - T - - -- - - l-3 3 Description and data - 4-6 6 OPERATING INSTRUCTIONS Service upon receipt of materiel - - 7-10 18 Controls and instrumenta - --_----_- - 11-41 20 Operation under usual conditions 42-63 26 Operation of materiel used in conjunction with 64,66 57 major item. Operation under unusual conditions w-61 40 ORGANIZATIONAL MAINTENANCE INSTRUCTIONS Parts, special tools, and equipment for operation 62-66 a8 and organizational maintenance. Lubrication and painting 66-72 60 Preventiv* maintmance service - 73-76 69 Troubleshooting -- -- 77-100 72 Engine description and maintenance in 101-113 106 vehicle. Eagine rwnoval aad Iartalletion _-_-- -_ 114-119 122 Cooling system - -_-- lb-126 146 Fuel and air intake system - 127-136 149 * This manual supersedes TBI 9-8Q4, 29 September lqsq, C 1, 16 February l%l, C 2, 18 May 1961, C 2, 10 April 1962: TB. ORD 479, 9 September 1%2; TB Q-8Q4-1, 8 July 1962; TB -2, 17 July 1962; TB -16 February 1959; TB 9-801-8,17 February 1955; TB 9-8Qk7,13 &larch 19%; TB w, 12 Bfarch 19%; TB Q-694-9, 29 May 1952; TB 9-60&10,16 Juue 1962; TB e 694-12, 9 March 19%; TB 9-894-12, 1 November 1966; TB 9-864-14, 19 Octoher 19&S; and ckoce e of TB ORD 247.14 26% 1961; TB ORD US. 7 May 1952; TB ORD 467,ll August lm2; TB ORD &IS,19 JJNI~UT 1962; I B ORD 49$, 4 Msrcb lq6s; TB ORD 547.19 December 1962; TB OBD 664, 7 January 19%; TB ORD 56Q, 19 Ma7 1954 pertaining to materiel c-red her&.. P
CHAPTER 1 INTRODUCTION Section I. GENERAL 1. Scope a. These instructions are published for the use of personnel to whom this materiel is issued. They contain information on the operation and organizational maintenance of the materiel as well as descriptions of major units and their functions in relation to other components of the materiel. b. The appendix contains a list of current references, including supply manuals, forms, technical manuals, and other available publications applicable to the materiel. c. This manual differs from TM 9-804, September 1950, as indicated in (1)) (2)) and (3) below. (1) Adds information on- (a) Plate showing OFF and ON positions under ignition switch, beginning with vehicle serial No. 26273. (b) A changed submersible starter mounting, beginning with vehicle serial No. 53262. Cc) A submersible generator, beginning with vehicle serial No. 53262. Cd) A sealed or pressurized bell housing, beginning with vehicle serial No. 53262. (e) A waterproof clutch linkage, beginning with vehicle serial No. 53262. (f) A l/s-inch hole in crankshaft pulley for timing purposes, beginning with vehicle serial No. 22296. (9) (h) (9 W Vent lines to bell housing, transfer case and transmission case, beginning with vehicle serial No. 53262. Decalcomania above deep water fording vent valve control, for locating bell housing drain plug and fording information, beginning with vehicle serial No. 53262. New engine rear plate for use with the changed starter mounting, beginning with vehicle serial No. 78513. Decalcomania on fuel tank cap, beginning with vehicle serial No. 14693. AGO 10167B 3
the supporting ordnance maintenance unit should be informed in order that trained personnel with suitable tools and equipment may be provided or other proper instructions issued, Note. The replacement of certain assemblies, that is, engine, transmission, transfer, and power-take-off assemblies, winch assembly, front axle, rear axle, and steering gear is normally an ordnance maintenance operation, but may be performed in an emergency by the using organization, provided approval for performing these replacements is obtained from the supporting ordnance officer. A replacement assembly, any tools needed for the operation which are not carried by the using organization, any necessary special instructions regarding associated accessories, etc., may be obtained from the supporting organizational maintenance unit. 3. Forms, Records, and Reports a. General. Responsibility for the proper execution of forms, records, and reports rests upon the officers of all units maintaining this equipment. However, the value of accurate records must be fully appreciated by all persons responsible for their compilation, maintenance, and use. Records, reports, and authorized forms are normally utilized to indicate the type, quantity, and condition of materiel to be inspected, to be repaired, or to be used in repair. Properly executed forms convey authorization and serve as records for repair or replacement of materiel in the hands of troops and for delivery of materiel requiring further repair to ordnance shops in arsenals, depots, etc. The forms, records, and reports establish the work required, the progress of the work within the shops, and the status of the materiel upon completion of its repair. b. Authorized Forms. The forms generally applicable to units operating and maintaining these vehicles are listed in the appendix. No forms other than those approved for the Department of the Army will be used. For a complete listing of all forms, see DA Pam 310-Z c. Field Report of Accidents. The reports necessary to comply with the requirements of the Army safety program are prescribed in detail in the SR 385-1040 series of special regulations. These reports are required whenever accidents involving injury to personnel or damage to materiel occur. d. Report of Unsatisfactory Equipment or Materials. Any suggestions for improvement in design and maintenance of equipment and spare parts, safety and efficiency of operation, or pertaining to the application of prescribed petroleum fuels, lubricants, and/or preserving materials or technical inaccuracies noted in Department of Army Publications, will be reported through technical channels, as prescribed in AR 700-38, to the Chief of AGO 10167B 5
Ordnance, Washington 25, DC, ATTN: ORDFM, using DA Form 468, Unsatisfactory Equipment Report. Such suggestions are encouraged in order that other organizations may benefit. Note. Do not report all failures that occur. Report only REPEATED or RECURRENT failures or malfunctions which indicate unsatisfactory design or material. However, reports will always be made in the event that exceptionally costly equipment is involved. See also AR 700-38 and printed instructions on DA Form 468. 4. Description Section II. DESCRIPTION AND DATA CL. General. The $&-ton 4 x 4 utility truck M38 is equipped with one front axle and one rear axle, with four driving wheels. The design of this vehicle locates the four-cylinder gasoline engine forward of the driving compartment, under the hood, and provides a four-passenger, open-type body. The body may be inclosed with removable canvas top, side curtains, and doors which are held in place and supported by suitable metal rods, braces, and canvas straps. The vehicle is used as a general purpose personnel or cargo carrier especially designed for adaptation to general reconnaissance, command, communications, or other special duties. The windshield can be folded forward to lie flat on the hood for low silhouette and forward firing. The spare wheel and tire are mounted on the rear of the body. Suitable brackets and compartments are incorporated in and on the body for carrying equipment. The frame is equipped with a towing pintle at the rear and lifting shackles at the front and rear to permit towing or lifting the vehicle. General physical characteristics of the vehicle are shown in figures 1, 2, and 3. The terms right, left, front, and rear are established with reference to the operator sitting in the driver s seat. Right indicates the side to the right of the operator. Left indicates the side to the left of the operator. Front indicates the radiator end of the vehicle. Rear indicates the end opposite the radiator. b. Engine. Power for the vehicle is supplied by an L-head, fourcylinder gasoline engine, mounted at three points on cushion mounts on the frame. The engine, with accessories, is accessible when the hood is in the raised position. c. Transmission. The conventional three-speed, selective-gear transmission is mounted directly to the rear of the engine and clutch assemblies. The transmission has three forward and one reverse speeds as indicated on the shifting instruction plate (fig. 4). These speeds are manually selected by the driver by means of the transmission gearshift lever. The lever is mounted on top 4 AGO 10167B
Figure 1. X-ton 4 CT 4 utility truck M38-left front view-top up.
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ro Figure 3. %-ton 4 1: 4 utility truck M38-top view-top down.