CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND DATA, AND THEORY OF OPERATION
GENERAL INFORMATION
LIST OF ABBREVIATIONS/ACRONYMS
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - APPLIQUE
EQUIPMENT DATA
EQUIPMENT DATA - CONTINUED
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS
DESCRIPTION AND USE OF OPERATOR CONTROLS - CONTINUED
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER UNUSUAL CONDITIONS
STOWAGE AND DECAL/DATA PLATE GUIDE
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL INFORMATION
INSPECTION INSTRUCTIONS
STANDARD TOOL REQUIREMENTS
DOOR HANDLE ASSEMBLY REPLACEMENT
DOOR HANDLE ASSEMBLY REPLACEMENT - CONTINUED
DOOR LATCH AND LOCK PIN REPLACEMENT
DOOR LATCH AND LOCK PIN REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
BLACKOUT DRIVE LIGHT REPLACEMENT
BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) APPLIQUE REPLACEMENT
CAB SIDE (REAR) APPLIQUE REPLACEMENT - CONTINUED
CAB SIDE (REAR) APPLIQUE REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
THE ARMY MAINTENANCE SYSTEM
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
Table 1. MAC for the Crew Protection Kit.
Table 1. MAC for the Crew Protection Kit - Continued
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items.
Table 1. Expendable and Durable Items - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL) INTRODUCTION
Source Code.
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
HOW TO LOCATE REPAIR PARTS
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 1 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 2 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 3 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 4 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 5 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 6 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 7 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 8 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 9 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 10 of 10)
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1A. Door Applique Armor Panel
Figure 1A. Door Applique Armor Panel - Continued
Figure 1B. Forward and Rear Applique Armor Panels
Figure 1B. Forward and Rear Applique Armor Panels - Continued
Figure 2. Roof Armor Kit and Mounting Hardware (Sheet 1 of 2)
Figure 2. Roof Armor Kit and Mounting Hardware (Sheet 2 of 2)
Figure 2. Roof Armor Kit and Mounting Hardware - Continued
Figure 3. Rear Armor Kit and Mounting Hardware
Figure 3. Rear Armor Kit and Mounting Hardware - Continued
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 1 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 2 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 3 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 4 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware - Continued
Figure 4. Underbody Armor Kit and Mounting Hardware - Continued
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 1 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 2 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 3 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 4 of 4)
Figure 5. Front Armor Kit and Mounting Hardware - Continued
Figure 5. Front Armor Kit and Mounting Hardware - Continued
Figure 6. Windshield Armor Kit and Mounting Hardware (Sheet 1 of 2)
Figure 6. Windshield Armor Kit and Mounting Hardware (Sheet 2 of 2)
Figure 6. Windshield Armor Kit and Mounting Hardware - Continued
Figure 7. Templates
Figure 7. Templates - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
ARMOR CREW PROTECTION KIT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
LIST OF TABLES
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
INTRODUCTION - Continued
Figure 1. PLS Armor Crew Protection Kit component locations.
DESCRIPTION AND OPERATION
PARTS LIST
Table 4. Parts List "Fasterner Kit, Side Armor Kits" P/N 113391-1
Table 5. Parts List "Armor Kit, Roof, PLS" P/N 113340-1-103
Table 7. Parts List "Armor Kit, Rear, PLS" P/N 113350-1-103
Table 10. Parts List "Armor Kit, Underbody, PLS, Fastener Kit" P/N 113394-1
Table 11. Parts List "Armor Kit, Front, PLS" P/N 113370-1-103
Table 13. Parts List "Armor Kit, Windshield, PLS" P/N 113380-1-103
Table 15. Parts List "Fastener Kit, Extra, PLS" P/N 113390-1
Table 15. Parts List "Fastener Kit, Extra, PLS" P/N 113390-1 (contd)
CREW PROTECTION KIT INSTALLATION
PERSONNEL SKILL LEVEL
Figure 3. Front Towing Shackles.
Figure 4. Cab Step.
Figure 5. Front vehicle components to be removed.
Figure 7. Blackout Light.
Figure 8. Marker Light and Headlight.
Figure 9. Marker Light access.
Figure 10. Side components to be removed.
Figure 11. Roof components to be removed.
Figure 12. Removal of the Glad Hands and Steering Link.
Figure 14. All of the items removed from the vehicle before installing the CPK.
INSTALLATION OF KIT COMPONENTS AND REMOVED ITEMS
Install Armor Kit, Windshield, PLS, P/N 113380-1-103
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Install Armor Kit, Side, PLS (LH), P/N 113310-1-103
Figure 23. Left Front Side Armor Assembly.
Figure 24. Door Hinge orientation.
Figure 25. Marker Light and Front Panel installation.
Install Armor Kit, Side, PLS (LH), P/N 113310-1-103 - Continued
Figure 26. Door Striker and Combat Latch locations.
Figure 27. Door Striker Support Hole locations.
Figure 28. Door Lifting Bracket.
Figure 29. Armored Door and Door Strap.
Figure 30. Mirror and Side Reflector installation.
Figure 31. Rear Side Panel Assembly.
Figure 32. Four-point restraint system (upper portion).
Figure 33. Four-point restraint system (lower portion, behind the seat).
Figure 34. Rear Side Panel installation (three-point restraint).
Figure 35. Rear Side Panel installation (four-point restraint).
Install Armor Kit, Side, PLS (RH), P/N 113310-2-103
Figure 36. Rear Armor Panels.
Figure 37. Rear Armor Panel installation.
Figure 38. Roof Assembly installation.
Figure 39. Installing the Escape Hatch Bulb Seal.
Figure 40. Escape Hatch Handle and Draw Latch installation.
Figure 41. Armored Roof Panel installation.
Figure 42. Installing the Antenna Mount, Left Side.
Figure 43. Installing the Antenna Mount, Right Side.
Figure 44. Installation of the Escape Hatch Brackets.
Figure 45. Escape Hatch and Front Roof Bracket installation.
Figure 46. The Upper Brush Guard Assembly.
Figure 47. Lower Brush Guard and Winch Cover.
Figure 48. Upper Brush Guard Armor Panels.
Figure 49. Lower Brush Guard Armor Panels.
Figure 50. Front Blackout Light.
Install Armor Kit, Front, PLS, P/N 113370-1-103
Figure 51. Left Headlight Assembly installation (Configuration A).
Figure 52. Right Headlight Assembly installation (Configuration A).
Install Armor Kit, Front, PLS, P/N 113370-1-103 - Continued
Figure 53. Left Headlight Assembly installation (Configuration B).
Figure 54. Right Headlight Assembly installation (Configuration B).
Figure 55. Winch Cover installation.
Install Armor Kit, Underbody, PLS, P/N 113360-1-103
Figure 56. Center Mineblast Plate Assembly installation.
Figure 57. Routing the Glad Hand line and Electrical Connector.
Figure 59. Steering Link, Torque Rod, Glad Hands, and Electrical Connector re-installed.
Figure 60. Left Mineblast Bracket location.
Figure 61. Underbody Attachment Bracket, Left Side.
Figure 62. Right Mineblast Bracket location.
Figure 63. Underbody Attachment Bracket, Right Side.
Install Armor Kit, Underbody, PLS, P/N 113360-1-103 - Continued
Figure 64. Cab Step Modification.
Figure 65. Underbody Armor, Left Side, installation.
Figure 66. Underbody Armor, Right Side, installation.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque Limits For Wet Fasteners
CREW PROTECTION KIT APPLIQUE INSTRUCTIONS
ARMOR KIT, SIDE, APPLIQUE INSTALLATION INSTRUCTIONS ANF PARTS LIST FOR THE APLLETIZED LOADING SYSTEM (PLS)
REVISIONS
TABLE OF CONTENTS
TABLE OF FIGURES
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
Figure 1-1. PLS Side Applique Armor component locations.
Figure 1-2. PLS Side Applique Armor crate layout.
WARNINGS, CAUTIONS, AND NOTES
COLOR OF COMPONENTS
Table 2. Parts List "PLS Side Applique Armor Kit" P/N 113301-1
Table 3. Parts List "Fasterner Kit, Side Applique Armor Kit" P/N 113397-1
SIDE APPLIQUE ARMOR KIT INSTALLATION
Install Armor Kit, Side Applique, PLS, P/N 113301-1
Install Driver's-Side Forward Applique Armor Panel (P/N 114602-1)
Figure 2. Preparation for Applique Armor Kit installation.
Figure 3. Installation of the Forward Applique Armor Panel.
Install Driver's-Side Door Applique Armor Panel (P/N 114601-1)
Figure 4. Installation of the Door Applique Armor Panel
Install Passenger-Side Door Applique Armor Panel (P/N 114601-1)
Figure 5. Installation of the Aft Applique Armor Panel.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque limits for fasteners
GENERAL INFORMATION
LIST OF ABBREVIATIONS/ACRONYMS
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - APPLIQUE
EQUIPMENT DATA
EQUIPMENT DATA - CONTINUED
THEORY OF OPERATION
CHAPTER 2. OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS
DESCRIPTION AND USE OF OPERATOR CONTROLS - CONTINUED
OPERATION UNDER USUAL CONDITIONS
OPERATION UNDER UNUSUAL CONDITIONS
STOWAGE AND DECAL/DATA PLATE GUIDE
CHAPTER 3. OPERATOR MAINTENANCE INSTRUCTIONS
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED
CLEANING BALLISTIC GLASS
CHAPTER 4. UNIT MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL INFORMATION
INSPECTION INSTRUCTIONS
STANDARD TOOL REQUIREMENTS
DOOR HANDLE ASSEMBLY REPLACEMENT
DOOR HANDLE ASSEMBLY REPLACEMENT - CONTINUED
DOOR LATCH AND LOCK PIN REPLACEMENT
DOOR LATCH AND LOCK PIN REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR BALLISTIC GLASS AND FRAME ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR ASSEMBLY REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR APPLIQUE REPLACEMENT - CONTINUED
DOOR LATCH ADJUSTMENT
DOOR LATCH ADJUSTMENT - CONTINUED
DOOR LATCH ADJUSTMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
WINDSHIELD BALLISTIC GLASS REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
UPPER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
LOWER BRUSH GUARD REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
HEADLIGHT AND COMPOSITE LIGHT REPLACEMENT - CONTINUED
BLACKOUT DRIVE LIGHT REPLACEMENT
BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ESCAPE HATCH ASSEMBLY MAINTENANCE - CONTINUED
ROOF ARMOR REPLACEMENT
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
ROOF ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (RIGHT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
REAR CAB (LEFT) ARMOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
SIDE BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CENTER BLAST DEFLECTOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) ARMOR REPLACEMENT - CONTINUED
CAB SIDE (REAR) APPLIQUE REPLACEMENT
CAB SIDE (REAR) APPLIQUE REPLACEMENT - CONTINUED
CAB SIDE (REAR) APPLIQUE REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) ARMOR AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CAB SIDE (FRONT) APPLIQUE AND SIDE MARKER REPLACEMENT - CONTINUED
CHAPTER 5. SUPPORTING INFORMATION
REFERENCES
THE ARMY MAINTENANCE SYSTEM
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED
Table 1. MAC for the Crew Protection Kit.
Table 1. MAC for the Crew Protection Kit - Continued
Table 2. Tools and Test Equipment Requirements for the Crew Protection Kit
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items.
Table 1. Expendable and Durable Items - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
FIELD MAINTENANCE (UNIT AND DIRECT SUPPORT MAINTENANCE) REPAIR PARTS AND SPECIAL TOOLS LISTS (RPSTL) INTRODUCTION
Source Code.
Maintenance Code
Recoverability Code
EXPLANATION OF CROSS-REFERENCE INDEXES WORK PACKAGE FORMAT AND COLUMNS
HOW TO LOCATE REPAIR PARTS
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 1 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 2 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 3 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 4 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 5 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 6 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 7 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 8 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 9 of 10)
Figure 1. Side Armor Kit and Mounting Hardware (Sheet 10 of 10)
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1. Side Armor Kit and Mounting Hardware - Continued
Figure 1A. Door Applique Armor Panel
Figure 1A. Door Applique Armor Panel - Continued
Figure 1B. Forward and Rear Applique Armor Panels
Figure 1B. Forward and Rear Applique Armor Panels - Continued
Figure 2. Roof Armor Kit and Mounting Hardware (Sheet 1 of 2)
Figure 2. Roof Armor Kit and Mounting Hardware (Sheet 2 of 2)
Figure 2. Roof Armor Kit and Mounting Hardware - Continued
Figure 3. Rear Armor Kit and Mounting Hardware
Figure 3. Rear Armor Kit and Mounting Hardware - Continued
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 1 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 2 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 3 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware (Sheet 4 of 4)
Figure 4. Underbody Armor Kit and Mounting Hardware - Continued
Figure 4. Underbody Armor Kit and Mounting Hardware - Continued
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 1 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 2 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 3 of 4)
Figure 5. Front Armor Kit and Mounting Hardware (Sheet 4 of 4)
Figure 5. Front Armor Kit and Mounting Hardware - Continued
Figure 5. Front Armor Kit and Mounting Hardware - Continued
Figure 6. Windshield Armor Kit and Mounting Hardware (Sheet 1 of 2)
Figure 6. Windshield Armor Kit and Mounting Hardware (Sheet 2 of 2)
Figure 6. Windshield Armor Kit and Mounting Hardware - Continued
Figure 7. Templates
Figure 7. Templates - Continued
GROUP 94 REPAIR KITS
GROUP 94 REPAIR KITS - Continued
NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - Continued
NATIONAL STOCK NUMBER INDEX - Continued
PART NUMBER INDEX
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
PART NUMBER INDEX - Continued
CREW PROTECTION KIT INSTALLATION INSTRUCTIONS
ARMOR CREW PROTECTION KIT INSTALLATION INSTRUCTIONS AND PARTS LIST
REVISIONS
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
LIST OF TABLES
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
INTRODUCTION - Continued
Figure 1. PLS Armor Crew Protection Kit component locations.
DESCRIPTION AND OPERATION
PARTS LIST
Table 4. Parts List "Fasterner Kit, Side Armor Kits" P/N 113391-1
Table 5. Parts List "Armor Kit, Roof, PLS" P/N 113340-1-103
Table 7. Parts List "Armor Kit, Rear, PLS" P/N 113350-1-103
Table 10. Parts List "Armor Kit, Underbody, PLS, Fastener Kit" P/N 113394-1
Table 11. Parts List "Armor Kit, Front, PLS" P/N 113370-1-103
Table 13. Parts List "Armor Kit, Windshield, PLS" P/N 113380-1-103
Table 15. Parts List "Fastener Kit, Extra, PLS" P/N 113390-1
Table 15. Parts List "Fastener Kit, Extra, PLS" P/N 113390-1 (contd)
CREW PROTECTION KIT INSTALLATION
PERSONNEL SKILL LEVEL
Figure 3. Front Towing Shackles.
Figure 4. Cab Step.
Figure 5. Front vehicle components to be removed.
Figure 7. Blackout Light.
Figure 8. Marker Light and Headlight.
Figure 9. Marker Light access.
Figure 10. Side components to be removed.
Figure 11. Roof components to be removed.
Figure 12. Removal of the Glad Hands and Steering Link.
Figure 14. All of the items removed from the vehicle before installing the CPK.
INSTALLATION OF KIT COMPONENTS AND REMOVED ITEMS
Install Armor Kit, Windshield, PLS, P/N 113380-1-103
Figure 15. Windshield Bracket, Side Mounting.
Figure 16. Windshield Bracket, Bottom Mounting.
Figure 17. Windshield Frame pre-assembly.
Figure 18. Position the Windshield Armor Frame into the cab windshield opening.
Figure 19. Urethane Sealant and Ribbon Sealer vehicle locations.
Figure 20. "L" Bracket Installation.
Figure 21. Armor Windshield installation.
Figure 22. Windshield Wiper and Cleaning Decal installation.
Install Armor Kit, Side, PLS (LH), P/N 113310-1-103
Figure 23. Left Front Side Armor Assembly.
Figure 24. Door Hinge orientation.
Figure 25. Marker Light and Front Panel installation.
Install Armor Kit, Side, PLS (LH), P/N 113310-1-103 - Continued
Figure 26. Door Striker and Combat Latch locations.
Figure 27. Door Striker Support Hole locations.
Figure 28. Door Lifting Bracket.
Figure 29. Armored Door and Door Strap.
Figure 30. Mirror and Side Reflector installation.
Figure 31. Rear Side Panel Assembly.
Figure 32. Four-point restraint system (upper portion).
Figure 33. Four-point restraint system (lower portion, behind the seat).
Figure 34. Rear Side Panel installation (three-point restraint).
Figure 35. Rear Side Panel installation (four-point restraint).
Install Armor Kit, Side, PLS (RH), P/N 113310-2-103
Figure 36. Rear Armor Panels.
Figure 37. Rear Armor Panel installation.
Figure 38. Roof Assembly installation.
Figure 39. Installing the Escape Hatch Bulb Seal.
Figure 40. Escape Hatch Handle and Draw Latch installation.
Figure 41. Armored Roof Panel installation.
Figure 42. Installing the Antenna Mount, Left Side.
Figure 43. Installing the Antenna Mount, Right Side.
Figure 44. Installation of the Escape Hatch Brackets.
Figure 45. Escape Hatch and Front Roof Bracket installation.
Figure 46. The Upper Brush Guard Assembly.
Figure 47. Lower Brush Guard and Winch Cover.
Figure 48. Upper Brush Guard Armor Panels.
Figure 49. Lower Brush Guard Armor Panels.
Figure 50. Front Blackout Light.
Install Armor Kit, Front, PLS, P/N 113370-1-103
Figure 51. Left Headlight Assembly installation (Configuration A).
Figure 52. Right Headlight Assembly installation (Configuration A).
Install Armor Kit, Front, PLS, P/N 113370-1-103 - Continued
Figure 53. Left Headlight Assembly installation (Configuration B).
Figure 54. Right Headlight Assembly installation (Configuration B).
Figure 55. Winch Cover installation.
Install Armor Kit, Underbody, PLS, P/N 113360-1-103
Figure 56. Center Mineblast Plate Assembly installation.
Figure 57. Routing the Glad Hand line and Electrical Connector.
Figure 59. Steering Link, Torque Rod, Glad Hands, and Electrical Connector re-installed.
Figure 60. Left Mineblast Bracket location.
Figure 61. Underbody Attachment Bracket, Left Side.
Figure 62. Right Mineblast Bracket location.
Figure 63. Underbody Attachment Bracket, Right Side.
Install Armor Kit, Underbody, PLS, P/N 113360-1-103 - Continued
Figure 64. Cab Step Modification.
Figure 65. Underbody Armor, Left Side, installation.
Figure 66. Underbody Armor, Right Side, installation.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque Limits For Wet Fasteners
CREW PROTECTION KIT APPLIQUE INSTRUCTIONS
ARMOR KIT, SIDE, APPLIQUE INSTALLATION INSTRUCTIONS ANF PARTS LIST FOR THE APLLETIZED LOADING SYSTEM (PLS)
REVISIONS
TABLE OF CONTENTS
TABLE OF FIGURES
LIST OF ACRONYMS AND ABBREVIATIONS
INTRODUCTION
Figure 1-1. PLS Side Applique Armor component locations.
Figure 1-2. PLS Side Applique Armor crate layout.
WARNINGS, CAUTIONS, AND NOTES
COLOR OF COMPONENTS
Table 2. Parts List "PLS Side Applique Armor Kit" P/N 113301-1
Table 3. Parts List "Fasterner Kit, Side Applique Armor Kit" P/N 113397-1
SIDE APPLIQUE ARMOR KIT INSTALLATION
Install Armor Kit, Side Applique, PLS, P/N 113301-1
Install Driver's-Side Forward Applique Armor Panel (P/N 114602-1)
Figure 2. Preparation for Applique Armor Kit installation.
Figure 3. Installation of the Forward Applique Armor Panel.
Install Driver's-Side Door Applique Armor Panel (P/N 114601-1)
Figure 4. Installation of the Door Applique Armor Panel
Install Passenger-Side Door Applique Armor Panel (P/N 114601-1)
Figure 5. Installation of the Aft Applique Armor Panel.
APPENDIX A. FASTENER TORQUE VALUES
Table A-1. Torque limits for fasteners