Operator's Manual

Truck Utility, Light 4 x 4 Military Design Iltis Canadian Series
Issued on Authority of the Chief of the Defence Staff
OPI: DSVPM
1985-7-15
1997-10-25 Ch 2

1.This manual contains operating instructions for the Truck, Utility, Light, 4×4, Military Design, litis Canadian Series. The manual also includes maintenance instructions at an operator's level.

2.The manual provides the operator with the necessary information for safe and trouble-free operation of the truck.

3.All correspondence concerning this manual should be directed to:

1.The Light Utility Trucks are divided into the following configurations:

2.The Light Utility series of trucks is designed for use over all types of road, cross-crountry terrain, and all weather conditions. The truck will ford hard bottom bodies of water, to a depth of 60 cm (23.6 in.) without special fording equipment. Figure 1-2-1 illustrates the Basic Light Utility Truck.

3.Trucks are powered by a 4-cylinder 1.7 litre gasoline engine. A five-speed manual transmission which includes a cross-country gear, is coupled to the front and rear differentials which in turn direct power to the front and rear wheels.

4.Single wheels are fitted to both the front and rear axles.

5.This vehicle has two separate brake systems:

6.The Light Utility Trucks are equipped with electrical connectors and pintle hooks, making them suitable for towing trailers.

7.The trucks are equipped with removable, canvas-covered superstructures which provide all-weather protection for the driver and passengers. Four separate doors are removable.

8.A spare wheel assembly (tire and rim) mounted on the rear of the body, provides an emergency spare wheel assembly change for vehicle or trailer.

9.Figures 1-2-2, 1-2-3, 1-2-4, 1-2-5, 1-2-6, and 1-2-7 contain, in tabular form, data of the basic truck series.

10.Identification, instruction and precautionary plates and decals are located on the vehicle. See Figure 1-2-8 for their locations. Figure 1-2-9 illustrates these items.

1.Figure 2-1-1 illustrates the location of vehicle gauges, instruments and indicators, except those located in the speedometer head, which will be found in Figure 2-1-2. Paragraphs describing those items found in each illustration use bracketed numbers to refer to call-outs.

2.This gauge, see Figure 2-1-1 (8), indicates the engine oil pressure when the engine is running. When driving, normal pressure is 200 kPa at approximately 2,000 rpm at normal operating temperature. Lower oil pressure readings are normal at idle.

3.This gauge (11) indicates the temperature of the engine coolant. Normal operating temperature is 90°C to 95°C.

4.This gauge (13) indicates the condition of the batteries and whether the charging system is charging the batteries. When the accessory switch is turned on, the gauge indicator should be in the green zone, if the batteries are adequately charged. When the engine is running, the gauge indicator should be in the green zone, indicating that the charging system is working.

5.When lit, the red warning light (10) indicates that the rear differential lock is engaged.

6.When lit, the amber warning light (12) indicates that the front wheel drive is disengaged. This is an abnormal driving condition. Four-wheel drive should be selected as soon as possible.

7.The brake warning light (9) lights when the hand brake is engaged and/or when the fluid in either brake fluid reservoir is low.

8.The speedometer, see Figure 2-1-2 (1), indicates the forward speed of the vehicle in kilometers per hour. The odometer, (10) in the lower centre of the speedometer, indicates the total kilometers travelled by the vehicle up to six digits.

9.When the accessory switch is on, the gasoline gauge (2) indicates the approximate quantity of gasoline in the gasoline tank. The tank holds 82 litres. When the needle reaches the beginning of the reserve zone, there are about 10 litres of gasoline in the tank.

10.The oil pressure warning light (5) will light when the oil pressure drops below 45 kPa indicating that the oil pressure is below operating level. The red warning light will light when the accessory switch is turned on and should go out as the engine starts. If the light comes on while driving, immediately stop and check the engine oil level (refer to Part 7, Section 3, "Operator Maintenance Instructions" and Part 7, Sections 5, "Troubleshooting").

11.The battery/alternator warning light (7) shows red if the alternator is not providing current to the vehicle electrical system. If this occurs, stop the engine and check the drive belts. Do not drive without a drive belt as the alternator and coolant pump are not being driven.

12.The red warning light (8) will light at 120°C to indicate that the engine temperature is too high. When driving at slow speed for extended periods during hot weather, excessive engine speed may cause overheating. Shift up to the next higher gear if this can be done without lugging the engine and without using full throttle. If not, reduce engine speed. If the light does not go out shortly afterwards, park the vehicle and allow engine to cool at a fast idle (refer to Part 7, Section 3, "Operator Maintenance Instructions" and Part 7, Sections 5, "Troubleshooting").

13.The engine oil temperature warning light (9) will light when the engine oil temperature is too high. High oil temperature is caused by excessive engine coolant temperature (see paragraph 12) and excessive engine load. Reduce engine load by working the vehicle less hard. If the light does not go out very shortly afterwards, park vehicle and allow engine to cool at a fast idle until the light goes out, then stop engine and check oil level (refer to Part 7, Section 3, "Operator Maintenance Instructions" and Part 7, Sections 5, "Troubleshooting").

14.When flashing, the green light (6) indicates that one of the following lighting systems is in operation:

The directional turn signal indicator is engaged by the turn signal lever.

15.The green light (4) when lit, indicates that the trailer turning signals are operating correctly. When there is not a trailer in tow, the indicator light will flash once when the turn signals are engaged.

16.When lit, the blue light (3) indicates the headlight high beams are on.

1.The master light switch assembly (3), see Figure 2-1-1, is composed of the following:

2.The turn signal lights will not function unless the main switch lever is in either the “SERVICE DRIVE” or “STOPLIGHT” position. The turn signal lights lever (2), Figure 2-1-1, can be placed in any of four positions:

3.The accessory switch (4) has two positions; the switch lever is moved clockwise to the “ON” position and counterclockwise to the “OFF” position. The accessory switch activates the following circuits:

4.Press the starter button (18) to crank the engine for starting. Release the button as soon as the engine starts. The button is spring loaded and returns automatically to the off position.

5.The windshield wipers and washer work only when the accessory switch is “ON”. The control lever (6) may be used in the following positions:

6.The control knob labelled “TEMP” (17) controls the amount of heat inside the vehicle. When the knob is fully out, maximum heat is available. Heat is off when the control is pushed all the way in.

7.The heater blower switch (16) controls the flow of air through the heating system. The accessory switch must be on for the blower to operate. The lower half of the heater blower switch controls the two blower speeds:

Push the top half of the switch to turn the blower off. To defrost the windshield, ensure that both heater footwell vents (14) are closed.

8.The hazard warning light switch (15) can be used when the main light switch lever is in the “SERVICE DRIVE” or the “STOPLIGHT” position. To turn on the hazard warning lights, press the lower half of the switch. The front and rear turn signal lights will flash. To turn off the hazard warning lights, press the top half of the switch.

9.The choke control (19) regulates the choke when starting a cold engine. Pull out the choke control before pressing the starting button and gradually push in as the engine warms.

10.The horn plate (20) is located in the centre of the steering wheel. Pressure applied anywhere to the plate will sound the horn.

11.Controls the carburetor throttle. To adjust the carburetor throttle using the throttle control (7) depress the accelerator pedal to open the carburetor throttle to the desired setting. While still depressing the accelerator pedal, pull out the throttle control until it holds the carburetor throttle at the desired setting. Turn the throttle control one quarter turn clockwise to lock into position. Release the accelerator pedal. To release the throttle control, turn one quarter turn counterclockwise and push in.

12.The vehicle is equipped with two quick-release windshield locking levers (1), one on each side of the dash at the bottom corners of the windshield, which lock the windshield in the upright position. To release the two fasteners from the hooks on the windshield frame, pull up on the release handles and swing the clamps free of the windshield hooks.

13.Pull open the heater footwell vents (14) to direct the flow of air in the heater system downward to the footwell. The amount of air directed downward can be controlled by adjusting the vent openings; when the vents are completely closed, all air flow is directed to the windshield vent openings.

14.The vehicle is always operated in four-wheel drive. To disengage four-wheel drive, push the lever down. To engage four-wheel drive, pull the lever up. Four-wheel drive can be engaged and disengaged when the vehicle is in motion. The actual engagement which occurs with a slight time delay , is effected by spring pressure on the transaxle linkage. The vehicle can be driven in any gear when the four-wheel drive mode is engaged. A light on the dash will come on when the vehicle is in two-wheel drive, see Figure 2-2-2, indicating an abnormal driving condition.

15.To engage the rear differential lock, pull up on the rear differential lock lever, see Figure 2-2-2. The vehicle may be stationary or moving forward or reverse at low speeds. Do not engage the rear differential lock at high speeds or if the rear wheels are spinning. Disengage when not required.

16.To apply the hand brake, see Figure 2-2-2, pull up the hand brake lever. To release, push the hand brake lever all the way down. The knurled knob, located at the end of the hand brake lever, controls the hand brake cable tension. With the brake off, turn the knob left to tighten the cable and right to slacken. The warning light will come on when the brake is applied.

17.The shift pattern, engraved on the knob of the transmission shift lever, see Figure 2-2-3, shows the position of the gear lever in the various gear positions. Cross-country (G) and reverse (R) gears cannot be engaged unless the collar on the shift lever is lifted. Wait a few seconds, with the clutch pedal fully depressed, before engaging reverse. The cross-country gear can be engaged only when the vehicle is in four-wheel drive. The vehicle must be completely stopped before engaging the cross-country gear.

18.The battery master switch, see Figure 2-2-4, is located under the dash on the left-hand side. The switch is used to connect and disconnect the 24-volt battery supply to all accessories except the alternator, starter and radios.

19.The slave receptacle, see Figure 2-2-5, located under the dash to the left of the driver, is used to start the vehicle from another vehicle.

20.To adjust the front seat backrest, rotate the adjusting wheel located at the bottom of the backrest, see Figure 2-2-6, until the desired position is reached. Do not adjust the backrest when the rear seats are in the forward position; interference and damage by the rear seat lock may result.

21.To adjust the front seats forward or backward, lift the seat catch, located under the front seats, and slide the seat forward or backward to the required position.

22.To tip the front backrest forward, lift the backrest lock, see Figure 2-2-7, located at the side of the backrest nearest the door until the backrest releases and it can be tilted forward.

23.To tip the rear seats forward, pull the loop located between the seat and its backrest. The backrest will release and the seat can then be tipped forward. To return the seat to its original position, pull the backrest upright and engage in the retainer.

24.There are seat belts for an operator and three passengers. Adjust the belts for a proper fit by holding the lock tongue at right angles to the belt and pulling the section of the belt to be lengthened or shortened. The surplus length is taken up by moving the plastic slide.

25.To light the map reading light located on the underside of the dash in front of the co-driver's seat, see Figure 2-2-8, slide the cover open. The master light switch lever must be in either of the service positions.

26.The mirror is adjustable. The mirror can be removed for camouflage purposes by twisting it free from the mounting socket.

27.The vehicle is equipped with two sun visors located above the windshield, one on the driver's side and one on the co-driver's side.

28.The superstructure locks secure the tarp to the frame of the windshield. To release the clips, lift the locking levers up.

1.Fully depress clutch pedal, see Figure 2-3-1, before changing gears. The clutch disengages the transmission from the engine for gear changes.

2.Depress the brake pedal, see Figure 2-3-1, to apply the brakes. The brakes make use of a hydraulic and vacuum system; pressure on the pedal is increased by a brake servo and transmitted through the master cylinder to the hydraulic wheel cylinders in each brake assembly. The hydraulic wheel cylinder pistons force the brake shoes against the brake drums.

3.The accelerator pedal, see Figure 2-3-1, controls the engine speed (revolutions per minute).

1.Hood Latches - The hood is held in place by two rubber holddown latches. Pull up on the latches and unhook them from the hood brackets to release the hood. Lift the latches and hook them into the hood brackets to secure the hood, see Figure Figure 2-4-1.

2.A-Frame Lugs - The vehicle is equipped with two A-frame lugs on the front bumper, see Figure 2-4-1.

3.Lifting Eyes - Used for recovery purposes, but not for emergency towing with a chain.

4.Hood Safety Catch - After releasing the two hood latches lift the hood and press the hood safety catch to the right, see Figure 2-4-2.

5.Hood Support Rod - With the hood raised, unhook the rod from the clip and insert it into the hole provided in the hood reinforcement, see Figure 2-4-3.

6.Windshield Holddown Straps - Rubber straps, see Figure 2-4-4, located on each side of the hood, engage in the upper windshield lock levers to secure the windshield in the lowered position.

7.Door Stowage Loops - Six holddown loops on the vehicle hood are used to secure the door bag when it is in use, see Figure 2-4-4.

8.Windshield Washer Spray Nozzles - The windshield washer spray nozzles, located on the hood near the windshield, are adjustable, and are used in conjunction with the windshield wipers to clean the windshield, see Figure 2-4-5.

9.Shovel Bracket - The bracket assembly is located on the underside of the hood and consists of a blade retainer, a shaft retaining bracket, and a handle holddown strap. To stow the shovel, place the blade in the blade retainer, insert the shaft into the retaining bracket, and close the bracket. Wrap the holddown strap over the handle and clip it to the loop on the hood, see Figure 2-4-6.

10.Headlight Adjusting Levers - Each headlight has an adjusting lever, see Figure 2-4-7, that directs the headlight beam vertically. When the vehicle is lightly loaded, the lever must be in the “NORMAL” position. When the vehicle is heavily loaded, turn the lever 90 degrees counterclockwise to adjust the headlight beams downward.

11.Engine Oil Dipstick - Measures the oil level in the engine oil pan, see Figure 2-4-8.

12.Engine Oil Filler Cap - Covers the oil filler opening, see Figure 2-4-8.

13.Radiator Expansion Reservoir Filler Cap - Covers the expansion reservoir filler opening, see Figure 2-4-9. Before removing the expansion reservoir cap, refer to Part 7, Section 3, paragraph 16.

14.Brake Fluid Reservoir Caps — Cover the brake fluid reservoir filler openings, see Figure 2-4-9. Each cap is equipped with an electrical fluid level sending unit.

15.Windshield Washer Reservoir Cap — Covers the windshield washer reservoir filler opening, see Figure 2-4-9.

16.Spare Wheel Assembly — Consists of a tire and a rim, see Figure 2-4-10.

17.Spare Wheel Assembly Carrier — The carrier, which secures the spare wheel assembly to the vehicle, consists of a mounting bracket and wheel supports, see Figure 2-4-11.

18.Gasoline Tank Filler Cap — Turn the gasoline tank filler cap counterclockwise to open and clockwise to close, see Figure 2-4-11. Gasoline cap can be locked if required.

19.Trailer Power Outlet Receptacle — Provides electrical output for trailer lighting system, see Figure 2-4-11.

20.Pintle Hook — Used for Towing — To open the hook, withdraw the cotter pin, and pull the catch release handle and lift up. To close the hook, pull the movable part of the hook down. A spring-loaded catch automatically locks the movable part closed. Insert the cotter pin, see Figure 2-4-11.

21.Jerry Can Carrier — Consists of a mounting bracket and a retaining strap, see Figure 2-4-11.

22.Antenna Mounting Bracket — Located on the upper right rear of the body, the antenna mounting bracket supports the antenna mast, see Figure 2-4-11. Some vehicles are equipped with two rear antenna mounting brackets.

23.License Plate Light - IIluminates the license plate.

24.Flag Staff Brackets - Located on the left and right front fenders.

1.Rear view mirrors are fitted to both right and left sides of the body. These may be pushed against the side of the vehicle when traveling through wooded areas.

2.Weapon brackets are located beside the driver's and codriver's seats.

3.The bracket located on the left rear wheel housing holds the fire extinguisher, see Figure 2-5-1.

4.The radiator protection plate is stowed in front of the batteries (located under the rear seat), see Figure 2-5-2, and when installed in front of the radiator helps to maintain engine operating temperature during cold weather operation. This plate is also used in cross-country driving to prevent mud, leaves and branches from entering the radiator.

5.The axe is stowed in a bracket located in front of the batteries, see Figure 2-5-2.

6.The tool kit is stowed in the fender wells and consists of:

7.The jack assembly, consisting of a jack and a wooden block, is stowed in the front fender well and is used to lift the vehicle for wheel changing.

8.The four vehicle tie-down brackets located on the vehicle frame, are used to secure the vehicle during shipment, see Figure 2-5-3.

9.The wheel chock is stowed inside the vehicle, in front of the base of the transmission shift lever and beneath the heater footwell vents, see Figure 2-5-4. For use of the wheel chock, refer to Part 6, Section 1, paragraph 6.

10.The vehicle is equipped with stowage bags and camouflage covers for the tool kit and vehicle doors. Camouflage covers are provided for the headlights, side mirrors and windshield.

11.The steering wheel lock consists of a lock and rubber covered cable and is stowed in the fender well. When secured to the steering wheel, and the vehicle body, the vehicle steering wheel cannot be turned.

12.The passenger safety chains consist of a vinyl covered chain with end clips and are stowed in the fender well. When the doors are removed, the safety chains must be installed across the door openings by connecting to loops on the vehicle. The safety chains provide additional driver and passenger security, but are not a substitute for seat belts.

1.It is essential that the following running-in rules are observed before operating new vehicles or vehicles with overhauled engines, transaxles or rear differentials.

During the next 500 km, the speed can gradually be increased to the maximum.

1.The tarp may be removed, folded and stored in the vehicle. To remove the tarp, proceed as follows:

2.To fold the tarp, proceed as follows:

3.After removing and folding the tarp, the vehicle superstructure may be removed, dismantled, stowed in its canvas bag and placed inside the tarp for storage. To remove the superstructure, proceed as follows:

4. The superstructure consists of a network of metal poles and rails, see Figure 3-2-6, that fit together and are locked in place with spring-loaded balls. To dismantle the superstructure, proceed as follows:

5.After placing the superstructure in the tarp, lay the tarp in- side and along the back of the vehicle and secure using the two tarp stowage straps, see Figure 3-2-8.

6.The front and rear doors may be stowed in the canvas bag supplied and secured to the hood. Clean the door windows and then proceed as follows:

7.Assemble the superstructure in the reverse order to which it was disassembled.

8.After assembling the superstructure, proceed as follows:

9.After securing the superstructure to the vehicle, proceed as follows:

10.Remove the five covers from the fender well under the hood.

11.To install the windshield cover, see Figure 3-2-11, proceed as follows:

12.To remove the windshield cover, proceed as follows:

13.To install the mirror covers, see Figure 3-2-12, proceed as follows:

14.To remove the mirror covers, proceed as follows:

15.To install the headlight camouflage covers, see Figure 3-2-13, place the headlight covers over the headlights and turn signal lights. Secure in place using the five snap fasteners on each cover.

16.To remove the headlight covers, unfasten the five snap fasteners on each cover and stow the covers in the fender well.

17.After removing the superstructure, the windshield can be left in an upright position or lowered and secured to the hood. The windshield may be lowered and secured either with or without the doors stowed on the hood. To lower the windshield, proceed as follows:

18.After lowering the windshield, see Figure 3-2-15, proceed as follows:

Reinsert the cotter pin into the top half of the pintle hook. h. Hook the trailer safety chains to the safety eyes on each side of the pintle hook. j. Open the spring-loaded cover on the trailer receptacle. k. While still holding the receptacle cover open, plug the intervehicular cable into the receptacle. m. Release the trailer receptacle cover. n. Release the hand brake on the trailer. p. Ensure all trailer lights operate.

19.To raise the windshield, proceed as follows:

20.To attach the trailer, see Figure 3-2-16, proceed as follows:

1.To fuel the vehicle, stop the engine and proceed as follows:

1.This part provides instructions for operating the vehicle under normal conditions, as defined in QSTAG 360.

2.The seat belts must be used by the operator and all passengers whenever the vehicle is in motion. Sudden braking will cause the front seat belts to lock. The locking mechanism will also lock the belts when driving down steep grades or cornering hard.

3.To fasten the driver's and co-driver's belts, proceed as follows:

4.To fasten the lap belts in the rear passenger seats, proceed as follows:

5.To release the belt, depress the red release button in the centre of the buckle and pull the latch plate from the buckle.

1.Perform "Before Starting Checks and Services". For instructions, see Part 7, Section 2.

2.To start the engine, proceed as follows:

3.Follow the procedure described in Part 4, Section 2, Starting a Cold Engine at Temperatures Below 20°C (68°F). Pull the choke control knob halfway out before starting the engine. After the engine is started, wait 40 seconds and then push the choke control knob in until it is only one quarter of the way out. Wait another 30 seconds and then push the choke control knob all the way in.

4.To shut down the engine after bringing the vehicle to a complete stop, proceed as follows:

1.This section provides instructions for putting the vehicle in motion. These instructions are applicable only after all ancillary equipment is stowed or is in the correct position for travel and the operator is seated.

2.Set the master light switch as required (refer to Part 2, Section 2).

3.Turn on the accessory switch and start the vehicle (refer to Part 4, Section 2).

4.To set the vehicle in motion proceed as follows:

5.If the vehicle is stopped on a grade, proceed as follows to put the vehicle in motion:

6.When down-shifting, proceed as follows:

7.To bring the vehicle to a stop, proceed as follows:

8.To drive in reverse, proceed as follows:

9.To drive in cross-country gear, proceed as follows:

10.When leaving the vehicle with the engine running, move the transmission shift lever to neutral and apply the hand brake before leaving the vehicle, to ensure the vehicle will not roll away.

1.This part describes only tnose procedures which differ from those discussed in Part 4, "Operating Under Normal Conditions". It details the special considerations and precautions necessary for operation under unusual conditions where extremes of temperature, humidity, and terrain are encountered.

2.Under extreme conditions, pay particular attention to all gauges and indicators. Early detection of a malfunction may prevent the need for more extensive repairs.

1.Extreme cold weather leads to difficult starting and troublesome operation. Consequently, preparation of the cooling, electrical and lubrication systems is of prime importance. Extreme cold weather creates the following problems:

2.The radiator protection plate is part of the vehicle kit and may be used as conditions dictate.

3.Refer to starting procedures in Part 4, Section 2.

4.After the engine has started, ensure that it is thoroughly warmed up before putting the vehicle in motion. Extreme cold increases the probability of equipment malfunction. Consequently, the operator must monitor the gauges and indicators during engine warm-up.

5.To put the vehicle in motion, proceed as follows:

6.Parking the Vehicle - When parking in extreme cold weather observe the following precautions:

7.Refueling the Vehicle - Ensure that the gasoline tank is topped up after operation; topping-up reduces condensation, and helps to prevent ice from forming in the fuel system. Ensure that all snow and ice is cleared from the gasoline dispensing equipment and the gasoline tank filler cap area.

8.Add isopropyl alcohol to prevent fuél line freeze-up.

9.Battery Removal - If the vehicle is not equipped with an arctic kit, and it is to be parked for a long period of time, remove the batteries and store them in a warm place. Warm batteries provide a greater reserve of power.

10.If there is an electrical outlet available, plug in the vehicle block heater.

11.If the vehicle is to be parked for a long period of time and the antifreeze in the vehicle cannot be made strong enough for the temperature conditions, have Maintenance drain the cooling system.

12.Engine oils, except sub-zero grade, will not pour at temperatures below -20°C (-4°F). Ensure that the vehicle has the correct engine oil for the temperature conditions so that the oil will flow immediately during engine start-up. It may take as long as two hours to warm the vehicle to an operable condition.

1.Overheating - Any of the following situations may cause overheating of the engine during extreme hot weather and should be avoided:

2.Cooling Off Period - If the tactical situation permits, and the engine is too warm, halt and raise the hood for a cooling off period.

3.Inspect the cooling system frequently, ensuring that there is sufficient coolant in the system.

4.Inspect the engine air intake frequently, and remove any foreign material.

5.Inspect the engine oil level frequently and add oil if required.

6.If the engine constantly overheats, refer to Part 7, Section 5.

7.To park the vehicle in extreme hot weather, proceed as follows:

8.Batteries - During very hot weather, batteries discharge rapidly when unused for extended periods. Where possible, store batteries in a cool place.

9.Body and Chassis - Corrosion, pitting, and paint blistering occur more frequently during hot, damp weather. Upholstery fabrics, tarpaulin, and rubber parts are likely to form mildew and mould, and to deteriorate very quickly under these conditions. Inspect the vehicle daily and clean where necessary. Report any blistering and pitting to Maintenance.

10.To ensure the batteries function normally in extreme hot weather, proceed as follows:

11.To maintain the cooling system in extreme hot weather, proceed as follows:

12.If the engine still overheats, report the fault to Maintenance. To maintain the vehicle body, proceed as follows:

1.Operating Procedure - When operating in deep snow, mud, or sand, use cross-country gear and avoid wheel spin to prevent burying the wheels to a point where the axle carrier rests on the ground. Apply rear differential lock if a wheel spins because of lack of traction.

2.After-Operation Checks and Services - After operation, proceed as follows:

3.Operating procedure - Skidding, loss of steering control and traction are the major problems encountered when operating on icy roads. Selection of the correct transmission drive gear, careful acceleration, and cautious application of the service brakes help to avoid skidding and consequent loss of steering control.

4.Skidding - When skidding occurs, immediately turn the front wheels in the direction of the skid.

5.Stopping Procedure - Exercise caution when braking on icy surfaces. Apply the service brakes gradually and intermittently to avoid skidding.

6.After-operation Checks and Services - After operating on icy roads, remove accumulated ice and snow from fenders, wheels, axles, radiator core, engine compartment, steering mecha- nism, air cleaner intake and gasoline tank filler cap. Check the constant velocity joint boots for damage.

7.Operating Procedure - Starting on Sandy Terrain - Proceed as follows:

8.Driving on Sandy Terrain - Proceed as follows:

9.Stopping on Sandy Terrain - Proceed as follows:

10.After-operation checks and services - Operation in dusty or sandy areas requires frequent servicing of the engine air intake system, fuel system, lubrication system and cooling system. After operating on sandy or dusty roads, proceed as follows:

11.Parking the Vehicle - Park in a sheltered area whenever possible. If blowing dirt or sand conditions exist, cover windshield glass and install the radiator protection plate in front of the radia- tor grille.

12.Operating Procedure - When operating in rocky terrain, make sure that tires are properly inflated. Over-inflation increases the shock transmitted to the vehicle, and under-inflation can cause internal rupture of tires. When checking tire pressures, do not reduce pressure when tires are hot after extended driving. Recom- mended tire pressures are for cold tires (see Figure 1-2-7). When driving over rocky terrain, do not attempt to straddle large boul- ders that will damage the axles or other low areas of the vehicle.

13.Operating Procedure - High altitude operation requires constant monitoring of engine coolant temperature and engine oil temperature. As altitude increases, the boiling point of coolant decreases. The pressurized cooling system should operate between 90°C and 95°C.

14.Inspect the Cooling System - Make regular inspections of the cooling system. Inspect all hose connections daily for signs of deterioration and leaks. Make sure that the expansion reservoir filler cap is on securely. Ensure the alternator belts have the correct tension.

15.The thinner air found at higher altitudes does not have enough oxygen to burn fuel completely. This problem may be offset by operating for shorter periods of time, reducing vehicle loads to compensate for the loss of engine power, and using lower gears to keep the engine rpm up.

16.If necessary, adjust the carburetor using the throttle control knob to increase engine idle rpm.

17.Operating Procedure - The ILTIS is capable of fording up to 60 cm. To ford a body of water, proceed as follows:

18.After-operation Checks and Services - After fording, proceed as follows:

19.After-operation Checks and Services - After driving crosscountry, inspect the brake system, steering, tires, wheels and lights for damage, twisting, and splits. Dry out the brake linings, if they are wet, by driving forward slowly and applying the brakes as necessary. Clean the light lenses and remove the radiator protection plate, if it was installed.

1.Blackout driving is used in tactical conditions. These are night-time, tactical situations in which a unit reduces to a minimum its chances of detection by the enemy. The use of blackout marker lights and blackout drive lights minimizes the risk of detection.

2.General - A blackout marker light is located at each of the four corners of the vehicle to indicate location of the vehicle under blackout conditions. The lights do not illuminate the road but indicate the position of a vehicle as much as 210 m (230 yd) ahead and behind, depending upon the weather. They cannot be seen from an aircraft flying more than 122 m (400 ft) above the vehicle.

3.Rear Tail Lights - Each rear light has a pair of “cat's eyes” that show red when on. Each pair appears as one light when the viewer is 55 m (180 ft) or more away, see figure 5-5-1, view A. When two distinct lights can be seen in each composite light, the viewer knows that the vehicle ahead is less than 55 m (180 ft) but more than 18 m (60 ft) away, see figure 5-5-1, view B. At less than 18 m (60 ft), the viewer sees two distinct “cats eyes” in each light, see figure 5-5-1, view C.

4.Front Lights - Each front light has a pair of “cat’s eyes” that show white when on. Each pair appears as one light when the viewer is 55 m (180 ft) or more away, see view A. When two distinct lights can be seen in each composite light, the viewer knows that the oncoming vehicle is less than 55 m (180 ft) but more than 18 m (60 ft) away, see view B. At less than 18 m (60 ft), the viewer sees two distinct “cat's eyes” in each light, see view C.

5.Located directly underneath the left front fender, the blackout driving light projects a low-intensity beam onto the ground in front of the vehicle. It is used when the road ahead of the vehicle must be illuminated just enough to allow safe, forward movement without revealing the vehicle position.

1.“Self-recovery” refers to those procedures which enable an operator to recover the vehicle by his own means.

2.To operate the jack, see Figure 6-1-1, proceed as follows:

3.To remove the spare wheel for use on the vehicle, proceed as follows:

4.To remove the wheel mounting adaptor, proceed as follows:

5.To change a vehicle wheel, proceed as follows:

6.To install a wheel assembly, proceed as follows:

7.After 50 km, verify that the wheel bolts are tight. Tighten to a torque of 175 N·m (129 ft Ib).

8.To change a trailer wheel, proceed as follow:

9.All trucks, Utility, Light, 4 X 4 will be fitted with wheel winch adapters (NSN 2530-21-898-2290) on the rear wheels for use with the self-recovery winching kit. The winching kit, see Figure 6-1-4, includes two winch drums (NSN 2590-21-898-2291) with a continuous 30 m (100 ft) drum nylon rope and load equalizer, a 15 m (50 ft) anchor line, a 2.4 m (8 ft) safety line and an installation tool, all contained in a nylon storage bag.

10.The wheel adapters shall be permanently installed on the rear wheels. To install the wheel adapters, proceed as follows:

11.The following instructions will enable the driver to selfrecover his vehicle from most situations.

12.The wheel winch is ruggedly constructed and designed for years of trouble-free service. The only maintenance required is to keep the unit clean and dry. This will avoid rope freeze-ups at low temperatures and ensure that it is always ready for use. The wheel adapter threads should be cleaned periodically and the drum bolt threads oiled occasionally.

13.Forces necessary to free the vehicle seldom approach the wheel winch’s maximum rating. Before reaching that level the engine will stall or the rope will break.

1.“Recovery” refers to those procedures that require the assistance of another vehicle.

2.Do not push or tow the vehicle if any component of the drive train is damaged. The drive train consists of the transaxle, propeller shaft, rear differential and drive axles.

3.Towing procedure is used only in emergency situations and makes use of a tow chain. It is used only to free a vehicle from such conditions as snow, sand, mud, or bog. It is not intended for towing a vehicle on roads for long distances. The towed vehicle should move under its own power as soon as possible. For emergency towing, proceed as follows:

4.This towing procedure is used only in emergency situations where one ILTIS must tow another ILTIS. It involves using an Aframe towing bar connected to the A-frame lugs on the front bumper of the disabled vehicle. Both vehicles must be unloaded and should not exceed 30 km/h, due to the reduced braking efficiency. It is not intended for towing a vehicle on public roads.

5.Long-distance towing involves moving a disabled vehicle for long distance, using a HLVW recovery truck and a qualified crew. Prior to towing, ensure that the disabled vehicle will not be damaged by towing. To tow the disabled vehicle, proceed as follows:

1.Position the serviceable vehicle with its slave receptacle side on the left side of the disabled ILTIS and proceed as follows:

1.Part 7 specifies those checks and services that must be done by the operator to keep the vehicle in a safe and serviceable condition and maximize the vehicle service life.

2.The operator must use only specified materials such as fluids, lubricants and filters when performing any service detailed in this part.

1.The operator will correct defects found during inspections if the defects are within his scope of responsibility.

2.Before operation - Inspect the following items each day before operating the vehicle:

Body

Under Vehicle

Engine Compartment

Inside Vehicle

3.During Operation - Check the following items each day during the operation of the vehicle:
Engine Start Up

Vehicle Operation

4.After Operation - Check the following items each day after operating the vehicle:

5.Weekly Inspection - Check the following items weekly:

6.Monthly Inspection - Perform the following tasks monthly:

1.Before and after operating the vehicle each day, inspect the brake system to ensure that the brake fluid level is between the minimum and maximum marks indicated on the brake fluid reservoirs. The reservoirs, located in the engine compartment, are translucent so that the brake fluid level can be seen easily. If the level of the fluid is below the minimum mark:

2.If the brake fluid level drops noticeably below the minimum mark in a short time (i.e., within a week), or if the brake pedal can be depressed to less than 10 cm from the floor, fluid may be leaking from the system. The following checks must be made:

3.The brake pedal must be tested daily to ensure that it does not rest less than 10 cm from the floor when fully depressed. To test the brake pedal:

4.The hand brake should be tested daily to ensure correct operation. To test the hand brake:

5.To test the light, proceed as follows:

6.Inspect the gasoline system daily before vehicle operation for leaks and loose connections. Secure or report loose connection or clamps to Maintenance.

7.The spin-on gasoline filter must be changed every 15,000 km or more frequently under adverse conditions. To change the gasoline filter:

8.Inspect the air intake system daily before vehicle operation by doing the following:

9.The air cleaner must be serviced every 15,000 km or more frequently under adverse conditions. The air filter element is a dry-type filter and must not be washed. To service the air cleaner, see Figure 7-3-5 and proceed as follows:

10.Before and after vehicle operation each day, inspect the exhaust system. See Figure 7-3-6 and proceed as follows:

11.The engine oil level must be checked daily before and after vehicle operation. The vehicle must be on a level surface. Do not check the oil immediately after stopping the engine as the oil takes about one minute to drain into the oil pan. Proceed as follows:

12.If the oil level on the dipstick is below the flattened portion of the dipstick, add more oil. Proceed as follows:

13.The engine oil will be changed during scheduled maintenance:

14.Allow the engine to warm up before changing the oil. To change the engine oil, proceed as follows:

15.Check the cooling system daily, before and after vehicle operation to ensure the following:

16.With the engine turned off and the hood of the vehicle raised, proceed as follows:

17.To ensure that all lights function, proceed as follows:

18.If one of the headlight bulbs will not light, see Figure 7-3-13, and proceed as follows:

19.If one of the park light bulbs does not light, proceed as follows:

20.The blackout drive light is located under the left front fender. If the blackout drive bulb does not light, proceed as follows:

21.To replace a front turn signal light bulb, proceed as follows:

22.If a front marker light does not light, see Figure 7-3-15 and proceed as follows:

23.Figure 7-3-16 identifies the bulbs in the composite taillight assemblies. If one of the lights in the tail assembly does not light, proceed as follows:

24.If the licence plate bulb will not light, proceed as follows:

25.The bulbs for the following gauges may be changed:

26.There is a bulb for each gauge. To replace a defective bulb, proceed as follows:

27.To replace the map reading light bulb, proceed as follows:

28.Inspect the heater and blower daily before operating the vehicle. With the engine running, proceed as follows:

29.Clean the receptacle daily before and after operating the vehicle. Proceed as follows:

30.Inspect the slave receptacle daily before and after operating the vehicle. The receptacle is located just below the battery master switch. To inspect the receptacle, proceed as follows:

31.There are two 12-volt batteries connected in series underneath the rear passenger seats. Inspect and clean the battery cable clamps monthly. Proceed as follows:

32.Inspect the electrolyte level weekly. To check the battery electrolyte, proceed as follows:

33.Perform this task monthly. To clean the batteries, proceed as follows:

34.To inspect and repair the electrical wiring, proceed as follows:

35.The reservoir, located in the engine compartment, holds 1.7 litres of fluid. When filling the reservoir, do not add water only. Cleaning fluid will better clean the windshield. In cold weather, use a window cleaning fluid with an antifreeze agent. Before operating the vehicle each day, check the fluid level and add fluid as required.

36.To add fluid proceed as follows:

37.Inspect the wipers daily before operating the vehicle. Proceed as follows:

38.Inspect the windshield washer daily before operating the vehicle. Before inspecting the windshield washer, ensure that the spray nozzles, located on the hood, are not covered over with mud, snow, ice or any other substance that could block the spray from the nozzles. Ensure that there is fluid in the windshield washer reservoir. With the accessory switch in the “ON” position, proceed as follows:

39.When the vehicle is stationary, the spray from the nozzles should strike the windshield in the upper third of the windshield wiper area. The spray nozzles, located on the hood, consist of two small balls each with a small hole. To adjust the direction of a spray. nozzle, insert a straight pin into the hole, see Figure 7-3-19, and move the ball using the pin. Remove the pin. After adjusting each ball, turn on the windshield washer and ensure that the spray hits the windshield in the correct area.

40.To replace windshield wiper blades, proceed as follows:

41.Proceed as follows:

42.Proceed as follows:

43.Perform the following tasks in accordance with the maintenance schedule:

1.This section details lubricants and service intervals for the vehicles.

2.This Lubrication Order applies only to vehicles in normal operation. Lubricate more frequently to compensate for abnormal or extreme conditions, such as high or low temperatures, immersion in water or exposure to sand or dust. Contaminated lubricants must be changed regardless of scheduled intervals.

3.Change the engine oil after the first 1,000 km and then every 7,500 km or every six months, whichever occurs first. Change the engine oil more frequently under adverse conditions such as fre- quent stopping and starting, trailer towing, dusty conditions and cold weather. To check engine oil level, wait about one minute after stopping the engine to allow oil to drain into the crankcase. For safe operation the oil level should show on the flattened portion of the dipstick, indicating that there is sufficient oil in the lubrication system.

4.Change the engine oil filter after the first 1,000 km and then during every oil change. When a new oil filter is installed during the oil change, add 4.5 litres of oil in the crankcase.

5.Top up the brake cylinder reservoirs to the level marks as required. Change the brake fluid when contaminated.

6.Inspect the dust boots of the constant velocity joints for damage at regular servicing intervals. Report torn or cracked dust boots to Maintenance.

7.Inspect the dust boots of the constant velocity joints for damage at regular servicing intervals. Report torn or cracked dust boots to Maintenance.

8.Grease every 5,000 km or more frequently during adverse conditions.

9.Each month, top up to the edge of the rear differential filler hole as required and change if contaminated. The capacity of the rear differential is 1.6 litres.

10.Each month, top up to the edge of the transaxle filler hole as required and change if contaminated. The capacity of the transaxle is 3.6 litres.

11.Inspect the dust boots for damage at regular servicing intervals. Report torn or cracked dust boots to Maintenance.

12.Lubricate the hood and windshield frame hinges with SAE 30 oil at regular servicing intervals.

13.Do not lubricate springs, leaves of springs, alternator, shock absorbers or wishbone rubber bushings.

14.The spin-on gasoline filter must be changed every 15,000 km or more frequently under adverse conditions.

15.Use antifreeze and water to maintain a coolant mixture of 60% antifreeze and 40% water ensuring that antifreeze is compatible with aluminum; the correct antifreeze is TL-VW774A G-10. Drain and replace the antifreeze every two years or 30,000 km. The capacity of the cooling system is 7.5 litres.

16.To be replaced every 7,500 km under conditions of extreme dust and every 15,000 km under normal conditions.

1.The troubleshooting guide will help determine the cause of malfunctions and recommend corrective action. The guide includes tests, inspections, adjustments and repairs that are within the operator's scope of responsibility. If operator's authorized repair or adjustment does not remedy the malfunction, notify Maintenance.