ARMY TM 9-2320-272-24-1

AIR FORCE TO 36A12-1C-1155-2-1

This publication supersedes TM 9-2320-272-20-1, October 1985, and changes 1 through 4; TM 9-2320-272-20-2,
October 1985, and changes 1 through 3; TM 9-2320-272-34-1, June 1986, and chanaes 1 through 2;
TM 9-2320-272-34-2, June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, October 1992

TECHNICAL MANUAL
VOLUME 1 OF 4
UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT
MAINTENANCE MANUAL
FOR
TRUCK, 5-TON, 6X6, M939, M939A1, M939A2
SERIES TRUCKS (DIESEL)

HOW TO USE THIS MANUAL

INTRODUCTION

l-l

SERVICE AND TROUBLESHOOTING

INSTRUCTIONS

2-l

PREVENTlVE MAINTENANCE CHECKS

AND SERVICES (PMCS)

2-2

UNIT TROUBLESHOOTING

UNIT

MAINTENANCE

2-60

3-1

TRUCK, CARGO: 5-TON, 6X6, DROPSIDE,

M923 (2320-01-050-2084) (EIC: BRY); M923Al (2320-01-206-4087) (EIC: BSS); M923A2 (2320-01-230-0307) (EIC: BS7);
M925 (2320-01-047-8769) (EIC: BRT); M925Al (2320-01-206-4088) (EIC: BST); M925A2 (2320-01-230-0308) (EIC: B58);
TRUCK, CARGO: 5-TON, 6X6 XLWB,
M927 (2320-01-047-8771) (EIC: BRV); M927A1 (2320-01-206-4089) (EIC BSW); M927A2 (2320-01-230-0309) (EIC: BS9);
M928 (2320-01-047-8770) (EIC: BRU); M928Al (2320-01-206-4090) (EIC: BSX); M928A2 (2320-01-230-0310) (EIC: BTM);
TRUCK, DUMP: 5-TON, 6X6,
M929 (2320-01-047-8756) (EIC: BTH); M929Al (2320-01-206-4079) (EIC: BSY); M929A2 (2320-01-230-0305) (EIC: BTN);
M930 (2320-01-047-8755) (EIC: BTG); M930Al (2320-01-206-4080) (EIC: BSZ); M930A2 (2320-01-230-0306) (EIC: BTO);
TRUCK, TRACTOR: 5-TON, 6X6,
M931 (2320-01-047-8753) (EIC: BTE); M931Al (2320-01-206-4077) (EIC: BS2); M931A2 (2320-01-230-0302) (EIC: BTP);
M932 (2320-01-047-8752) (EIC: BTD); M932Al (2320-01-205-2684) (EIC: BS5); M932A2 (2320-01-230-0303) (EIC: BTQ);
TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6,
M934 (2320-01-047-8750) (EIC: BTB); M934A1 (2320-01-205-2682) (EIC: BS4); M934A2 (2320-01-230-0300) (EIC: BTR);
TRUCK, MEDIUM WRECKER: 5-TON, 6X6,
M936 (2320-01-047-8754) (EIC: BTF); M936Al (2320-01-206-4078) (EIC: BS6); M936A2 (2320-01-230-0304) (EIC: BTT).
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

JUNE 1998

ARMY TM 9-2320-272-24-l
AIR FORCE TO 36A12-1C-1155-2-l
HEADQUARTERS
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
Washington,D.C., 30 JUNE 1998

TECHNICAL MANUAL
NO. 9-2320-272-24-1
TECHNICAL ORDER
NO. 36A12-1C-1155-2-1

TECHNICAL MANUAL
VOLUME 1 OF 4
UNIT, DIRECT SUPPORT, AND
GENERAL SUPPORT MAINTENANCE MANUAL
FOR
TRUCK, 5TON, 6X6, M939, M939A1, M939A2 SERIES TRUCKS (DIESEL)
TRUCK

MODEL

EIC

NSN WITHOUT WINCH

Cargo, Dropside
Cargo, Dropside
Cargo, Dropside
Cargo, Dropside
Cargo, Dropside
Cargo, Dropside
Cargo
Cargo
Cargo
Cargo
Cargo
Cargo
Dump
Dump
Dump
Dump
Dump
Dump
Tractor
Tractor
Tractor
Tractor
Tractor
Tractor
Van, Expansible
Van, Expansible
Van, Expansible
Medium Wrecker
Medium Wrecker
Medium Wrecker

M923
M923Al
M923A2
M925
M925Al
M925A2
M927
M927Al
M927A2
M928
M928Al
M928A2
M929
M929Al
M929A2
M930
M930Al
M930A2
M931
M93lAl
M931A2
M932
M932Al
M932A2
M934
M934Al
M934A2
M936
M936Al
M936A2

BRY
BSS
BS7
BRT
BST
BS8
BRV
BSW
BS9
BRU
BSX
BTM
BTH
BSY
BTN
BTG
BSZ
BTO
BTE
BS2
BTP
BTD
BS5

2320-01-050-2084
2320-01-206-4087
2320-01-230-0307

BTQ

BTB
BS4
BTR
BTF
BS6
BTT

NSN WITH WINCH

2320-01-047-8769
2320-01-206-4088
2320-01-230-0308
2320-01-047-8771
2320-01-206-4089
2320-01-230-0309
2320-01-047-8770
2320-01-206-4090
2320-01-230-0310
2320-01-047-8756
2320-01-206-4079
2320-01-230-0305
2320-01-047-8755
2320-01-206-4080
2320-01-230-0306
2320-01-047-8753
2320-01-206-4077
2320-01-230-0302
2320-01-047-8752
2320-01-205-2684
2320-01-230-0303
2320-01-047-8750
2320-01-205-2682
2320-01-230-0300
2320-01-047-8754
2320-01-206-4078
2320-01-230-0304

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications
and Blank Forms), or DA Form 2028-2 located in back of this manual, directly to: Director, Armament and
Chemical Acquisition and Logistics Activity, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630. A reply
will be furnished to you. You may also provide DA Form 2028-2 information via datafax or e-mail:
E-mail:am&a-ac-nml.@ria-emh2.army.mil
Fax: DSN 783-0726 or commercial (309) 782-0726
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
i

TM 9-2320-272-24-1
*This publication supersedes TM 9-2320-272-20-1,24 October 1985, and changes 1 through 4; TM 9-2320-272-20-2,25
October 1985, and changes 1 through 3; TM 9-2320-272-34-1, 10 June 1986, and changes 1 through 2; TM 9-2320-272-34-2,
10 June 1986, and changes 1 and 2; and TM 9-2320-358-24&P, 21 October 1992.
This publication is published in four volumes. TM 9-2320-272-24-1 contains chapters 1,2, and 3 (through
section IX). TM 9-2320-272-24-2 contains chapters 3 (sections X through XVI) and 4 (sections I through III).
TM 9-2320-272-24-3 contains chapter 4 (sections IV through XVI). TM 9-2320-272-24-4 contains chapters 5 and
6 and appendices A through H. Volume 1 contains a table of contents for the entire manual. Volumes 1,2, and 3
contain an alphabetical index covering tasks found in their respective volume. Volume 4 contains an
alphabetical index covering all tasks found in the entire manual.

TABLE OF CONTENTS
VOLUME 1 OF 4
Page

HOW TO USE THIS MANUAL

CHAPTER 1
Section I.
Section II.
Section III.
CHAPTER 2
Section I.
Section II.

INTRODUCTION

...................................................
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND TROUBLESHOOTING INSTRUCTIONS

l-l
l-l
l-5
l-25
2-l

Repair Parts; Tools; Special Tools; Test, Measurement,

and Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . . . . . . . . . . . .
ServiceUponReceipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-l
2-l

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

Section IV.

UNIT TROUBLESHOOTING PROCEDURES

Section I.
Section II.
Section III.
Section IV
Section V.
Section VI.
Section VII.
Section VIII.
Section IX
Section X.
Section XI.
Section XII.
Section XIII.
Section XIV
Section XV
Section XVI.

..................

Section III.

CHAPTER 3

ii

........................................

UNIT MAINTENANCE

. . . . . . . . 2-2

...........................

..............................................
Engine System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Intake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission and Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shafts, Axles, and Suspension System Maintenance . . . . . . . . . . . . . . . . . . . . .
Compressed Air and Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels, Hubs, Drums, and Steering Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body, Cab, and Accessories Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winch and Power Takeoff (PTO) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Purpose Bodies Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Purpose Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Central Tire Inflation System (CTIS) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-60
3-l
3-l
3-41
3-55
3-139
3-149
3-220
3-353
3-403
3-476
3-615
3-683
3-730
3-823
3-869
3-968
3-1231

TM 9-2320-272-24-1

TABLE OF CONTENTS (Contd)

Page

CHAPTER 4
Section I.
Section II.
Section III.
Section IV
Section V
Section VI.
Section VII.
Section VIII.
Section M.
Section X.
Section XI.
Section XII.
Section XIII.
Section XIV.
Section XV
Section XVI.
CHAPTER 5
Section I.
Section II.
Section III.
Section IV.
Section V.
Section VI.
Section VII.

DIRECT SUPPORT (DS) MAINTENANCE

..............................
Direct Support (DS) and General Support (GS) Mechanical Troubleshooting . . . . . . . . . .
Power Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine (M939lAl) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine (M939A2) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TransmissionMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressed Air and Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body, Cab, and Hood Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Purpose Bodies Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winch, Hoist, and Power Takeoff (PTO) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Purpose Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SUPPORT (GS) MAINTENANCE INSTRUCTIONS

.............

Engine (M939/Al) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine (M939A2) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Purpose Bodies Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Winch, Hoist, and Power Takeoff (PTO) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-l
4-1
4-35
4-117
4-271
4-352
4-388
4-465
4-504
4-548
4-584
4-605
4-681
4-691
4-715
4-808
4-1002
5-l
5-l
5-157
5-280
5-398
5432
5-463
5-606

SHIPMENT AND LIMITED STORAGE INSTRUCTIONS

6-l
6-l
6-2
6-2

APPENDIX A

REFERENCES

A-l

APPENDIX B

MAINTENANCE ALLOCATION CHART

B-l
B-l
B-4
B-25
B-26

EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST

C-l
C-l
C-3

MANDATORY REPLACEMENT PARTS

D-l

CHAPTER 6
Section I.
Section II.
Section III.

Section I.
Section II.
Section III.
Section IV
APPENDIX C
Section I.
Section II.
APPENDIX D

.................
General Preparation of Vehicle for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LoadingandMovement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.....................................................

...............................
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool and Test Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
............
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Introduction
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..........
Expendable/Durable Supplies and Materials List
...............................

iii

TM 9-2320-272-24-1

APPENDIX E

COMMON AND SPECIAL TOOL IDENTIFICATION LIST

APPENDIX F

ILLUSTRATED LIST OF MANUFACTURED ITEMS

APPENDIX G
APPENDIX

iv

TORQUE LIMITS

................

. . . . . . . . . . . . . . . . F-l

...................................................

SCHEMATIC AND WIRING DIAGRAMS

E-l

................... .............

G-l
H-1

TM 9-2320-272-24-l

HOW TO USE THIS MANUAL

ABOUT YOUR MANUAL
Spend some time looking through this manual. Youll find that it has a new look, different than most
TMs youve been using, including its predecessors, TM 9-2320-272-20-1, TM 9-2320-272-20-2,
TM 9-2320-272-34-1, TM 9-2320-272-34-2, and TM 9-2320-358-24&P.
New features added to improve the convenience of this manual and increase your efficiency are:
a. Accessing Information - These include physical entry features such as the bleed-to-edge
indicators on the cover and edge of the manual. Extensive troubleshooting guides for specific
systems lead directly to step-by-step directions for problem solving and maintenance tasks.
b. Illustrations -A variety of methods are used to make locating and fixing components much easier.
Locator illustrations with keyed text, exploded views, and cut-away diagrams make the information
in this manual easier to understand and follow.
c. Commonality - Only items that are unique to a specific series or vehicle will be given a separate
procedure. When only minor differences occur, notes are added to tell you to alter the normal
procedure in one way or another to accommodate the differences.
d. Keying Text with Illustrations - Instructions/text are located together with illustrations of the
specific task you are performing. In most cases, the task steps and illustrations are located on
facing pages, with text on the left and illustrations on the right. Continue reading for an example of
modular text and illustration layout,

HOW TO USE THIS MANUAL

Heres an example of how to use your manual:
Task: The unit maintenance mechanic of an M939 series vehicle reports that the engine cranks but fails to
start.
Troubleshooting steps:

1.
2.

Look at the cover of this manual. Youll see subjects listed from top to bottom on the right-hand side.
Look at the right edge of the manual. On some of the pages youll see black bars (edge indicators)
that are aligned with the subject bars on the cover. These are the locations of the subjects in the
manual.

3.
4.

Look for UNIT TROUBLESHOOTING in the subject list on the cover,

Turn to the page with the edge indicator matching the subject bar for UNIT TROUBLESHOOTING.
Page numbers are also listed next to the subject titles.
An edge indicator is placed on the first page of the UNIT TROUBLESHOOTING.
NOTE
If the first page of a subject has an even-numbered page, it will
appear on your left, but the edge indicator will still be on the page to
your right. So, if the information you are looking for does not start on
the page to your right, it will on the page to your left.
Look down the list until you find ENGINE. Beneath that heading you will find the symptoms noted
by the maintenance mechanic: Engine cranks, fails to start.
Turn to the page indicated: page 2-9.
On page 2-9, steps/test relating to resolving the malfunction of Engine cranks, fails to start, are:
Step 1. You inspect the fuel pump shutoff valve and find it is defective and must be replaced. You
see para. 4-6 referenced.
Step 2. The rest of the inspection shows no other cause for the problem.
Locate para. 4-5, and you will find the detailed procedure for removing the old fuel pump shutoff
valve and replacing it with a new one.

5.

6.
7.
8.

9.

TM 9-2320-272-24-1

HOW TO USE THIS MANUAL (Contd)

10.

11.

12.

vi

NOTE
Before starting the maintenance task, look through the entire
procedure to familiarize yourself with it.
a. The entire procedure (4-5. FUEL PUMP SHUTOFF REPLACEMENT), according to the THIS
TASK COVERS header, includes: a. Removal and b. Installation.
b. The nine basic subheadings listed under INITIAL SETUP outline the task preconditions,
materials, tools, manpower requirements, and general safety instructions. They are:
APPLICABLE MODELS: Any models that require that particular maintenance task.
TEST EQUIPMENT: Test equipment needed to complete a task.
SPECIAL TOOLS : Those tools required to complete the task.
MATERIALS/PARTS: All parts or materials required to complete the task.
PERSONNEL REQUIRED: The number and type of personnel needed to accomplish a task.
NOTE
If you think you need more help to correctly or safely complete the
task (perhaps as a result of an unusual condition, etc.), alert your
supervisor and ask for help.
REFERENCES(TM): Those manuals required to complete the task.
EQUIPMENT CONDITIQN Notes the conditions that must exist before starting the task.
For (4-5. FUEL PUMP SHUTOFF REPLACEMENT), the hood must be raised and secured
(TM 9-2320-272-10), and the left splash shield removed (TM 9-2320-272-10).
SPECIAL ENVIROMENTAL CONDITIONS: Outlines specific environmental conditions
necessary to perform the task. For example: Darken an area when adjusting headlight
beams.
GENERAL SAFETY INSTRUCTIONS: Summarizes all safety warnings for the
maintenance task.
c. A step-by-step maintenance procedure follows the INITIAL SETUP.
d. At the end of the procedure, FOLLOW-ON TASK(S) will list those additional task(s) that must be
performed to complete the procedure. The follow-on tasks for 4-5. FUEL PUMP SHUTOFF
REPLACEMENT are: Start engine (TM 9-2320-272-10), check fuel pump shutoff valve for proper
operation (TM 9-2320-272-101, install left. splash shield (TM 9-2320-272-10), and lower and secure
hood (TM 9-2320-272-10X
Refer to our example procedure, 4-5. FUEL PUMP SHUTOFF REPLACEMENT as we review the
following points:
a. Modular Text: Both pages of text and illustrations are to be used together. This manual was
designed so that the two pages are visible at once, making part identification and procedure
sequence easy to follow.
b. Initial Setup: Outlines task conditions.
c. Illustrations: An exploded view of the components removed from the vehicle shows part
locations, attachments, and spatial relationships.
Refer to TM 9-2320-272-24P, Unit, Direct Support, and General Support Maintenance Repair Parts
and Special Tools List for Truck, 5-Ton, 6x6, M939, M939A1, M939A2 Series Trucks, when
requisitioning parts and special tools for Unit, Direct Support, and General Support maintenance,
Your manual is easier to use once you understand its design. We hope it will encourage you to use it
more often.

TM 9-2320-272-24-1

CHAPTER 1
INTRODUCTION
Section I.
General Information (page 1-1)
Section II. Equipment Description and Data (page l-5)
Section III. Principles of Operation (page 1-25)

Section I. GENERAL INFORMATION

1-1. SCOPE
a. This manual contains information and instructions needed to service and maintain 5-ton, 6x6, M939,
M939A1, and M939A2 (M939/A1/A2) series vehicles by unit, direct support, and general support
maintenance personnel. This manual is intended to be used in conjunction with TM 9-2320-272-10 and
TM 9-2320-272-24P for overall completion of tasks found in this manual.
b. The vehicle model numbers and description of vehicles covered in this manual are:
Table 1-1. Vehicle Cross-Reference Table.
VEHICLE DESCRIPTION
Truck, Cargo, Dropside,
Without Winch (WO/W)

M939 SERIES
M923 (EIC: BRY)

M939Al SERIES
M923Al (EIC: BSS)

M939A2 SERIES
M923A2 (EIC: BS7)

Truck, Cargo, Dropside,

With Winch (W/W)

M925 (EIC: BRT)

M925Al (EIC: BST)

M925A2 (EIC: BS8)

Truck, Cargo, Extra Long

Wheelbase (XLWB),
Without Winch (WO/W)

M927 (EIC: BRV)

M927Al (EIC: BSW)

M927A2 (EIC: BS9)

Truck, Cargo, Extra Long

Wheelbase (XLWB),
With Winch (W/W)

M928 (EIC: BRU)

M928Al (EIC: BSX)

M928A2 (EIC: BTM)

Truck, Dump,
Without Winch (WO/W)

M929 (EIC: BTH)

M929Al (EIC: BSY)

M929A2 (EIC: BTN)

Truck, Dump,
With Winch (W/W)

M930 (EIC: BTG)

M930Al (EIC: BSZ)

M930A2 (EIC: BTO

Truck, Tractor,
Without Winch (WO/W)

M931 (EIC: BTE)

M931Al (EIC: BS2)

M931A2 (EIC: BTP)

Truck, Tractor,
With Winch (W/W)

M932 (EIC: BRD)

M932Al (EIC: BS5)

M932A2 (EIC: BTQ)

Truck, Van, Expansible

M934 (EIC: BTB)

M934Al (EIC: BS4)

M934A2 (EIC: BTR)

Truck, Medium Wrecker

M936 (EIC: BTF)

M936Al (EIC: BS6)

M936A2 (EIC: BTT)

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed
by DA Pam 738-750, The Army Maintenance Management System (TAMMS).

l-l

TM 9-2320-272-24-1

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army materiel to prevent enemy use can be found in TM 750-244-6.

1-4. PREPARATION FOR STORAGE OR SHIPMENT

Storage and shipment instructions are found in chapter 6. Additional information can be found in
TM 740-90-1, Marking, Packing, and Shipment of Supplies and Equipment: General Packaging Instructions
for Field Use.

l-5. OFFICIAL NOMENCLATURE

The nomenclature, names, and designations used in this manual are in accordance with
MIL-HDBK-63038-2.

l-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs);

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and
Blank Forms), or DA Form 2028-2 located in back of this manual direct to: Commander, U.S. Army Tankautomotive and Armaments Command, ATTN: AC-NML, Rock Island, IL 61299-7630. A reply will be
furnished to you.

1-7. WARRANTY INFORMATION

The 5-ton, 6x6, M939/Al series vehicle Cummins engine (model NHC 250) and Allison transmission
(model MT564CR) are warranted in accordance with TB 9-2300-295-15/21. The warranty starts on the date
found in block 23, DA Form 2408-9, in logbook. Report all defects in material or workmanship to your
supervisor, who will take appropriate action.

1-8. ARMY PETROLEUM, OILS, AND LUBRICANTS (POL)

Proper disposal of hazardous waste material is vital to protecting the environment and providing a safe
work environment. Materials such as batteries, oils, and antifreeze must be disposed of in a safe and
efficient manner.
The following references are provided as a means to ensure proper disposal methods are followed:
Technical Guide No. 126 (from the U.S. Army Environmental Hygiene Agency)
National Environmental Policy Act of 1969 (NEPA)
Clean Air Act (CAA)
Resource Conservation and Recovery Act (RCRA)
Comprehensive Environmental Response, Compensation, and Liability Act
Emergency Planning and Community Right to Know Act (EPCRA)
Toxic Substances Control Act (TSCA)
Occupational Health and Safety Act (OHSA)
The disposal of Army Petroleum, Oils, and Lubricants (POL) products are affected by some of these
regulations. State regulations may also be applicable to POL. If you are unsure of which legislation affects
you, contact state or local agencies for regulations regarding proper disposal of Army POL.

l-2

TM 9-2320-272-24-1

1-9. USE OF METRIC SYSTEM

The equipment/system described herein contains metric common and special tools; therefore, metric units
in addition to U.S. standard units will be used throughout this publication.

1-10. LIST OF ABBREVIATIONS

AOAP - Army Oil Analysis Program
bx- box
CAGEC - Commercial and Government Entity Code
cm - centimeter
CTIS - Central Tire Inflation System
cu-ft - cubic feet
cu-yd - cubic yard
cuM - cubic Meter
ea - each
ft - feet
GM - Grease, Automotive and Artillery
GTW - Gross Towed Weight
gal. - gallon
in. inch
kg- kilograms
km/h - kilometers per hour
km/L - kilometers per liter
kPa - kiloPascal
L - liter
lb-ft - pound-feet
lb - pound
max - maximum
min - minimum

mm - millimeter
mpg - miles per gallon
mph - miles per hour
Nm - Newton meter
NATO - North Atlantic Treaty Organization
OZ - ounce
para. - paragraph
PMCS - Preventive Maintenance Checks and
Services
POL - Petroleum, Oils, and Lubricants
psi - pounds per square inch
pt - pint
PTO - Power Takeoff
qt - quart
rpm - revolutions per minute
SEA - Standard, Engineering, and Automotive
TMDE - Test, Measurement, and Diagnostic
Equipment
U/M - Unit of Measure
W/W - With Winch
WO/W - Without Winch
XLWB - Extra Long Wheelbase

1-11. GLOSSARY
APPROACH ANGLE - Angle between front tire and front bumper
DEPARTURE ANGLE - Angle between rear tire and rear bumper
FORDING - Crossing through water
GRADE - Steepness of terrain
HYDRAULIC - Operated by oil pressure
OPERATOR - Driver of vehicle
PAULIN - Canvas cover or tarpaulin (tarp)
SLAVING -Jump starting

1-3/( 1-4 blank)

TM 9-2320-272-24-1

Section II. EQUIPMENT DESCRIPTION AND DATA

l-l2. EQUIPMENT DESCRIPTION AND DATA INDEX
PARA.
NO.
1-13.
1-14.
1-15.
1-16.
1-17.

TITLE
Equipment Characteristics, Capabilities, and Features
Location and Description of Major Components
Differences Between Models
Equipment Data
Description of Data Plates

PAGE
NO.
1-5
1-16
l-20
1-22
l-24

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

a. The M939, M939A1, and M939A2 (M939/A1/A2) series of vehicles are varied in design and
capabilities. The M939 was a redesign and retrofit of the MS09 series of vehicles, providing enhanced
capabilities.
(1) The leading features of the M939 are:
(a) Automatic transmission (Allison MT654)
(b) Hydraulic-assisted power steering system
(c) Complete airbrake system
(d) Improved cooling system
(e) Three-crewmember cab
(f) Tilt hood
(2) Changes were incorporated into later production engines (after engine serial number 11246663)
which provided for control of exhaust gas recirculation back to the air intake manifold and the use of topstop injectors to make up a clean air configuration.
(3) The M939Al improved on the M939 by adding 14:00xR20 super-sized tires, increasing the
minimum road clearance and approach and departure angle. This necessitated a modification to the spare
tire rack and lifting device used on all series vehicles.
(4) The M939A2 incorporated a new engine (Cummins 6CTA8.3) and the Central Tire Inflation System
(CTIS).
b. The M939/A1/A2 series vehicles can be distinguished from the M809 series by the following features:
(1) On the left side, the exhaust was moved behind the cab and tilted out so exhaust gases clear the
side of the vehicle. Hood latches were installed on the sides of the hood near the mirrors. The battery box
was incorporated into the companion seat to improve battery life in cold climates. A steering-assist cylinder
was installed between the right front frame rail and the right axle hub.
(2) From the front, the hood and fenders are an assembly which tilt forward for access to the engine
compartment. A tilt handle and locking device was installed to tilt and hold the hood in a secured open
position.
(3) The air filter was moved under the drivers door and the intake stack was brought up behind the
cab, even with the cab top.

1-5

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

c. Cargo Trucks With Dropsides: M923/A1/A2 WO/W and M925/A1/A2 W/W.
PURPOSE: These models are used to transport cargo and troops. The vehicles have a payload rating of
10,000 lbs (4,540 kg) and provide 550 cu-ft (15.4 CuM) of cargo space. Removable dropsides and tailgate
permit hauling of extra wide loads and easy access for unloading cargo. Troop seats, bows, and canvas are
also available. The M925/A1/A2 models have front winches and can be used for recovery operation. The bed
of the M923A1/A2 and M925Al/A2 has been shifted back to facilitate a new lifting davit and spare tire
mount. When the tire is mounted in its storage location on the M923A1/A2 and M925Al/A2, the top of the
tire extends above the minimal reducible height and may need to be removed to obtain the necessary
measurement.

1-6

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

(Contd)

1-7

TM 9-2320-272-24-1

1-l3. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

d. Cargo tick With Extra Long Wheelbase (XLWB): M927/A1/A2 WO/W and M928/A1/1A2 W/W.
PURPOSE: These models are used to transport troops and longer cargo loads. They have the same
characteristics as the M923/Al/A2 and M925/A1/A2, but have additional 76 in. (193 cm) of bed space that
allows an extra 194 cu-ft (5.4 cuM) of cargo space. Troop seats, bow, and tarpaulin are available. This
vehicle has permanent steel-welded sides. The M928/A1/A2 model vehicles have winches and can be used
for recovery operations. The bed of the M923A1/A2 and M925A1/A2 has been shifted back to facilitate a
new lifting davit and spare tire mount. When the tire is mounted in its storage location on the M923A1/A2
and M925A1/A2, the top of the tire extends above the minimal reducible height and may need to be
removed to obtain the necessary measurement.

1-8

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

1-9

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

e. Dump Truck: M929/A1/A2 WO/W and M930/A1/A2 W/W.
PURPOSE: These models are for hauling and dumping cargo. They have a capacity of 5 cu-yd
(3.84 cuM). The bodies have provisions for side racks and troop seats, and bow and tarpaulin for troop
transport. The M930/A1/A2 have front winches and can be used for recovery operations. Additional support
brackets have been designed on the M929A1/A2 and M930A1/A2 model vehicles and are available to
support the bed in a slightly raised position for removal of the 14:00xR20 spare tire.

1-10

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

1-11

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

f. Tractor Trucks: M931/A1/A2 WO/W and M932/A1/1A2 W/W.
PURPOSE: These vehicles are equipped with a fifth wheel and are used for hauling semitrailers. The
fifth wheel is capable of pivoting 21 degrees up, 15 degrees down, or 7 degrees sideways. The M932/A1/A2
model vehicles have front winches and can be used for recovery operations.

1-12

TM 9-2320-272-24-1

l-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

1-13

TM 9-2320-272-24-1

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

g. Expansible Vans: M934/A1/A2.
PURPOSE: These vehicles are used for electronics, maintenance, supply, power, and base station
operation. The van body can be expanded when set up in a stationary mode of operation; when mission
requires more mobile-type operation, the body is left in the retracted position.

1-14

TM 9-2320-272-24-l

1-13. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

h. Medium Wrecker: M936/Al/A2.
PURPOSE: These vehicles are used for wrecker and salvage operations. They have a revolving
hydraulic crane with a self-supported extendable boom. Boom-to-ground supports and outriggers are
provided. Crane lifting capacity is 20,000 lb (9,080 kg). The vehicle has a front winch with a 20,000 lb
(9,080 kg) capacity. M936/A1 models are equipped with front anchor brackets for heavy straight and side
pulls using the front winch. All models are equipped with a 45,000 lb (20,250 kg) capacity rear winch, rear
anchor brackets for heavy straight and side pulls, and spring brake override of the Power Takeoff (PTO) air
switch for self-recovery operations.

1-15

TM 9-2320-272-24-1

1-14. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

a. Exterior Components. The components described herein are common to most vehicles covered in this
manual. Specific differences can be found in TM 9-2320-272-10 or in table 1-2, Differences Between Models
(para. 1-15), of this manual.

LIFTING SHACKLE(S)
ENGINE
TRANSMISSION
PRIMARY AND SECONDARY AIR
RESERVOIRS
TRANSFER CASE
WET TANK RESERVOIR
REAR PROPELLER SHAFT(S)
UNIVERSAL JOINT(S)
SERVICE BRAKE CHAMBER
REAR BOGIE
SPRING BRAKE CHAMBER
TOWING PINTLE
REAR DIFFERENTIAL(S)
FUEL TANK(S)
SPARE TIRE CARRIER
AIR CLEANER

1-16

TM 9-2320-272-24-1

1-14. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Contd)

Key Item and Function
1 LIFTING SHACKLE(S) - Permit vehicle to be towed by another vehicle or used for tiedown
attachment when transporting vehicle.
2 ENGINE - There are two different Cummins model engines used, the NHC 250 (M939/A1 series
vehicles) and 6CTA8.3 diesel (M939A2 series vehicles), which provide mechanical power to the
vehicle and engine-driven subsystems.
3 TRANSMISSION - The Allison MT546CR automatic, used on all M939/A1/A2 series vehicles,
adapts the engines output for a varying range of operating speeds.
4 PRIMARY AND SECONDARY AIR RESERVOIRS - Provides storage of compressed air and
isolation between air subsystems.
5 TRANSFER CASE - Directs the engine and transmission output to the specified axles and/or
auxiliary equipment.
6 WET TANK RESERVOIR - Provides reserve storage of compressed air created by the air
compressor or external source when demand is low and releases it when required. This lessens the
cycling of the engine-driven air compressor.
7 REAR PROPELLER SHAFT(S) - Transmits power between transfer case and forward-rear axle
assemblies, and between forward-rear and rear-rear axles assemblies.
8 UNIVERSAL JOINT(S) - Provides a flexible point between a component and the propeller shafts.
This allows components that cannot maintain precision alignment to transfer power from one point
to another, without undue stress or breakage.
9 SERVICE BRAKE CHAMBER - Mechanical brake actuator that is activated by applying air
pressure to an expandable cylinder, causing it to apply braking force to the brakedrum.
10 REAR BOGIE - The suspension system comprised of both rear axles, upper and lower torque rods,
springs, and seats that support the rear vehicle weight.
11 SPRING BRAKE CHAMBER - Mechanical brake actuator that is spring-loaded to apply brakes
when air is low or not present. During normal vehicle operation, air piston counteracts the spring
tension and allows the brakes to release. Spring brakes can be bypassed by pushing in the spring
brake OVERRIDE switch on the instrument panel, or released using procedures found in TM 9-2320272-10.
12 TOWING PINTLE - Provides a secure quick-connect/disconnect for towing vehicles or equipment.
13 REAR DIFFERENTIAL(S) - Bi-directionally transfer power from the propeller shaft to the axles,
and provide a straight-through connection to power additional propeller shafts.
14 FUEL TANK(S) - Provides storage of fuel.
15 SPARE TIRE CARRIER - Stores spare tire.
D a v i t - Used to load and unload spare tire on M923/A1/A2, M925/A1/A2, M927/A1/A2,
M928/A1/A2, M931/A1/A2, and M9321/A1/A2 model vehicles.
Winch and Swinging Davit - Used to load and unload spare tire on M934A1/A2 model vehicles.
Optional kit is available for M934 model vehicle.
Hoist and Lifting Eye - Used to load and unload spare tire on M929/A1/A2, M930/A1/A2, and
M934 model vehicles. Optional kit is available to support dump bed in semi-raised position during
tire removal.
Vehicle Crane - Used to load and unload spare tire on M936/A1/A2 model vehicles. NOTE: On
M936/A1/A2 model vehicles, remove spare tire prior to changing tire, and install tire in spare tire
carrier after tire change is complete. Operation of crane and/or vehicle engine while vehicle is on
jacks may cause the vehicle to slip off jack.
16 AIR CLEANER - Filters air before it enters the intake manifold or turbocharger and collects dust in
removable section of filter canister.

1-17

TM 9-2320-272-24-1

1-14. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Contd)

b. Interior Cab Components. The components described herein are common to one or more vehicles
covered in this manual. Components not found here can be found in TM 9-2320-272-10 or in table 1-2,
Differences Between Models (para. 1-15), of this manual.

Key Item and Function

1 FRONT-WHEEL DRIVE LOCK-IN SWITCH - A pneumatic switch that permits front-wheel drive
to be engaged when the transfer case is in HIGH position. Operation of switch is not required when
transfer case is in LOW position; system will automatically switch into six-wheel drive.
1-18

TM 9-2320-272-24-1

1-14 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (Contd)

Key
2
3
4
5

6
7
8
9

10

11

12

13
14
15

16
17
18
19

Item and Function

POWER TAKEOFF (PTO) SPRING BRAKE OVERRIDE SWITCH - Used during rear winch
self-recovery operations of M936/A1/A2 model vehicles only. This air control switch must be held in to
override spring brake air dump switch on transfer case PTO lever.
INSTRUMENT PANEL - Houses controls and indicators.
TRANSMISSION SELECTOR LEVER - Manual control to select driving gear.
SPRING BRAKE OVERRIDE SWITCH - Pressed in to release spring brakes independent of the
mechanical parking brake for tests and adjustments. Can be used to release spring brakes in the
event a leak or stoppage occurs in lines between primary and spring brake reservoirs, or primary
system air shutoff valve is closed.
TRANSMISSION POWER TAKEOFF (PTO) LEVER - Used on M925/A1/A2, M928/A1/A2,
M929/A1/A2, M930/A1/A2, M932/A1/A2, and M936/A1/A2 model vehicles only. Provides hydraulic
power for front winch and/or dump body operation.
WINCH CONTROL LEVER - Provides control of winch unwinding and winding operations from
inside the cab.
TRANSFER CASE SHIFT LEVER SWITCH - Used in conjunction with transmission selector
lever in NEUTRAL position to allow transfer case to be shifted between HIGH and LOW gears.
PASSENGER SEAT - Combination two-person crew seat, battery box, and storage box. Seats are
equipped with two sets of seatbelts, the battery box houses four batteries, and the storage
compartment stores technical manuals. NOTE: Ensure companion seatbelts are not caught inside
battery box.
TRANSFER CASE SHIFT LEVER - Pushed down to shift transfer case into HIGH gear, center
position for NEUTRAL, and up position for LOW gear. When transfer case is placed in LOW, it will
automatically engage six-wheel drive. In HIGH, the instrument panel-mounted front-wheel drive
lock-in switch must be used to achieve six-wheel drive operation.
SPRING BRAKE CONTROL SWITCH - Senses the position of the parking brake control lever and
signals the spring brakes to engage when the lever is up and disengage when it is down. Spring
brakes can be tested independently from parking brake by raising this switch without pulling up the
parking brake control lever (TM 9-2320-272-10).
(a) DUMP BODY CONTROL LEVER - Used on M929/A1/A2 and M930/A1/A2 to control raising
(pulled back) and lowering (pushed forward) of dump body.
(b) TRANSFER CASE POWER TAKEOFF (PTO) - Used on M936/A1/A2 to control the hydraulic
pump that delivers hydraulic pressure to the rear winch and crane. A spring brake air dump switch
is installed on the lever when used on these vehicles, which engages the spring brakes. To override
this feature during self-recovery operation with the rear winch, the driver must depress and hold the
PTO spring brake override air switch on the instrument panel.
DUMP BODY CONTROL LEVER SAFETY LATCH - Secures dump body control lever or transfer
case PTO in NEUTRAL when not in use.
FUEL TANK SELECTOR LEVER - Used on dual tank model vehicles only. NOTE: Tanks must be
switched periodically to lessen the buildup of contaminants and fungus.
PARKING BRAKE CONTROL LEVER - Pulled up to set mechanical brake on output of transfer
case and to engage the spring brakes, and down to disengage brakes. Knob on top of handle is turned
clockwise to increase braking action on the output of transfer case, and counterclockwise to decrease
braking action. Spring brakes engagement is controlled by the spring brake control switch located on
the back of the lever.
ACCELERATOR PEDAL - Foot control to vary the speed of the engine.
BRAKE PEDAL -Applies the service brakes.
DIMMER SWITCH - Depressed to change between HIGH and LOW beam setting on headlights.
FUEL GAUGE TANK SELECTOR SWITCH - Used to switch fuel gauge to read either left or right
fuel tank. Installed only on dual tank model vehicles.
1-19