M939 M939A1 M939A2 5-Ton 6×6 Diesel Truck Maintenance Manual – TM 9-2320-272-34-2 Volume 2

Description

M939 M939A1 M939A2 5-Ton 6×6 Diesel Truck Maintenance Manual – TM 9-2320-272-34-2 Volume 2

This is Volume 2 of the Direct Support and General Support Maintenance manual for the M939, M939A1 and M939A2 series 5-ton, 6×6 diesel trucks. Published as TM 9-2320-272-34-2 / Air Force TO 36A12-1C-452-2 and updated through Change 2, this volume begins at Chapter 8 and carries the technician through the major assemblies that sit behind the engine and transmission: transfer case, front and rear axles, compressed air and brake systems, power steering, frame, front sheet metal, cab, cargo and dump bodies, fifth wheel, wrecker body, van body, winches, power takeoffs and the special purpose kits.

File Details

• Manual type: U.S. Army and U.S. Air Force Technical Manual – Direct Support and General Support Maintenance
• Document numbers: TM 9-2320-272-34-2 / TO 36A12-1C-452-2
• Manual title: Truck, 5-Ton, 6X6, M939, M939A1 and M939A2 Series (Diesel)
• Volume: 2 of 2 (Chapters 8-21, Appendices A-E)
• Publication date: 26 April 1990, Change 2 (1991)
• Page count: 1,312 pages
• Language: English
• File format: PDF

Chapters Covered

• Chapter 8 – Transfer Case Maintenance: description and data, interlock valve replacement, interlock valve (M936) replacement, interlock air cylinder, front axle engagement air cylinder, front axle engagement control valve, shift lever, shift lever shift rod, cross-shaft, shift rod, speedometer drive gear and driven shaft, switch, capacitor, transorb diode, oil pump, transfer case replacement, transfer case (M936) replacement, transfer case repair
• Chapter 9 – Front and Rear Axles Maintenance: description and data, spindle bearing sleeve and oil seal, steering knuckle assembly, front axle assembly replacement, front axle carrier differential assembly, differential and differential carrier, rear-rear axle assembly replacement, forward-rear axle assembly replacement, rear axle carrier differential assembly, upper and lower torque rod repair, front and rear differential oil seal replacement, cross tube replacement, steering stop adjustment, axle leakage test
• Chapter 10 – Compressed Air and Brake Systems Maintenance: description and data, air compressor, air compressor replacement, front and rear brake actuator repair, brake pedal (treadle) valve repair, relay valve, limiting valve, service brake brakedrum maintenance
• Chapter 11 – Power Steering System Maintenance: description and data, preliminary maintenance checklist, maintenance precautions, upper steering column replacement, lower steering column maintenance, steering gear (Ross) and mounting bracket replacement, steering gear (Sheppard) and mounting bracket replacement, steering gear repair, power steering assist cylinder repair, power steering pump test equipment setup, power steering tests and adjustments, power steering gear adjustment (on vehicle)
• Chapter 12 – Frame Maintenance: description and data, general frame maintenance, repair and replacement standards
• Chapter 13 – Front Sheet Metal Maintenance: description, hood crossmember bracket, hood hinges, torsion bars and crossmember, front fenders, radiator brush guard
• Chapter 14 – Cab Maintenance: description, cab door glass, cab windshield glass, retractable window glass and van door window glass, engine access cover (in cab), winch control lever and power takeoff control lever, transmission control console and winch control tower
• Chapter 15 – Cargo Body (M923, M924, M925, M926, M927, and M928) Maintenance: description and data, cargo body assembly, cargo body frame rail sill
• Chapter 16 – Dump Body (M929 and M930) Maintenance: description and data, dump body, dump roller arm, dump hoist cylinder, dump safety lock and cylinder, dump cab protector shield, dump safety brace, dump body hydraulic hose, dump valve cable and shift lever, dump subframe, dump hydraulic pump, dump control valve
• Chapter 17 – Fifth Wheel Maintenance: description and data, fifth wheel maintenance
• Chapter 18 – Wrecker Body (M936) Maintenance: fuel can bracket, hydraulic oil filter housing, hydraulic oil reservoir, hydraulic oil reservoir brackets and straps, hydraulic hoist winch motor and lines, hoist level wind, hoist winch, boom elevating cylinder, boom elevating cylinder packing, boom, inner boom, extension cylinder, boom roller, electrical swivel, hydraulic swivel valve, crane hydraulic swinger motor, crane swinger gearcase, crane control valve, regulator flow valve, gondola, turntable, front winch hydraulic pump, front winch control valve, component repair including hydraulic oil reservoir repair, hydraulic hoist winch motor or swinger motor repair, hoist winch repair, boom elevating cylinder repair, boom repair and adjustment, extension cylinder repair, boom roller repair, crane swinger gearcase repair, gondola repair, turntable repair, crane control valve repair
• Chapter 18.1 – Van Body (M934, M934A1, M935, M935A1) Maintenance: description and data, van body replacement, retractable beam drive shaft and lock, retractable beam, retractable beam rollers, rear doors, side doors, underframe parts, hinged floor, exterior side panel, rear wall interior panels, hinged end panel, interior side panels and latches, ceiling and frame, hinged roof, front wall registers, ceiling filler and side panels, ceiling rear cover, ceiling air ducts, ceiling transition, ceiling deflectors and registers, rear splice plate, bonnet frame parts, bonnet access door, bonnet door, and the complete van body electrical components section covering main wiring harness, air conditioner wiring harness, heater wiring harness, heater fuel pump wiring harness, 10kW electrical heater wiring harness, blackout bypass wiring harness, right and left side blackout harness, circuit breaker harness and circuit breaker, emergency lamp wiring harness, blackout and clearance lights wiring harness, 400 Hz supply and branched 400 Hz receptacle wiring harness, telephone post wiring harness, entrance receptacle 220V 3-phase wiring harness, flexible converter wiring harness, electrical load center box, electrical box, electrical junction box, 400 Hz converter outlet box, 400 Hz converter harness conduit, control center box, heater thermostat and 10kW heater thermostat, blackout and emergency light fixtures, AC manual starter switches, fluorescent light fixtures, 400 Hz converter, 3-phase receptacle wiring harness, and electrical load center conduit
• Chapter 19 – Winch Maintenance: description and data, front winch repair, front winch cable tensioner, front winch level wind, front winch roller assembly, front winch hydraulic pump replacement, front winch control valve cable, front winch control valve, front winch hydraulic hose and tube; rear winch repair, rear winch cable tensioner, rear winch side roller, rear winch top and bottom roller, rear winch hydraulic motor, rear winch level wind; repair and replacement standards
• Chapter 20 – Power Takeoff Maintenance: description and data, transfer case PTO control cable, transfer case PTO cross-shaft (control lever), transfer case power takeoff replacement, transfer case power takeoff repair, transmission PTO control cable, transmission PTO replacement, transmission PTO repair
• Chapter 21 – Special Purpose Kits: engine coolant heater kit replacement, personnel fuel burning heater kit replacement, deepwater fording kit, hand airbrake kit, radiator and hood cover kit, air conditioner kit
• Appendix A – References
• Appendix B – Repair Parts, Special Tools, and Equipment
• Appendix C – Expendable/Durable Supplies and Materials List
• Appendix D – Illustrated List of Manufactured Items
• Appendix E – Torque Limits

This M939 M939A1 M939A2 maintenance manual is the shop-floor reference for the driveline, chassis and body work that keeps these trucks in service. The transfer case chapters cover the two-speed unit with its air-operated front-wheel drive shift cylinder, electrically actuated interlock system and air-actuated interlock cylinder, along with the oil pump, speedometer drive and every external control. The axle chapters cover the hypoid double-reduction front axle and the tandem rear axles, including the carrier differentials, steering knuckles, spindle bearing sleeves, torque rods, cross tube and the axle leakage test. The compressed air and brake chapters cover the single-cylinder air compressor, brake actuators, treadle valve, relay valve, limiting valve and spring brake dash control valve. The power steering chapters cover both the Ross recirculating-ball gear with its worm and sector adjustments and the Sheppard shuttle valve and piston gear, plus the assist cylinder, pump test setup and the full test-and-adjustment sequence. Cab, sheet metal and body chapters cover the hood, fenders, radiator brush guard, cab glass, engine access cover, control consoles, six cargo body variants, two dump body models, fifth wheel, the M936 wrecker body with its hydraulic crane and outrigger-style boom functions, and the M934/M935 expansible van body with its retractable beam system and full 400 Hz, 220V 3-phase and DC electrical distribution. Winch and PTO chapters cover the front and rear winches, their cable tensioners, level winds, rollers and hydraulic motors, and both the transfer case and transmission power takeoffs. Chapter 21 covers the special purpose kits that were fitted for cold weather starting, deepwater fording, air braking of towed vehicles, radiator and hood protection, and air conditioning.

Each task in this M939 series DS/GS manual is presented with an initial setup listing applicable models, test equipment, special tools, materials and parts, personnel required, manual references, equipment condition, special environmental conditions and general safety instructions, followed by numbered steps with location, item, action and remarks columns. Torque values, clearances, wear limits, spring test readings and adjustment specifications are given in the procedures and consolidated in Appendix E. Appendix C lists expendable and durable supplies with national stock numbers. Appendix D shows items that can be manufactured in the shop. Appendix B points to the repair parts and special tools listings. Safety warnings and cautions are repeated at the point of use throughout.

Models Covered in This Manual

This volume covers the full M939 series family as listed on the manual’s title page: the M923 and M923A1 dropside cargo trucks, M924 and M924A1 cargo trucks, M925 and M925A1 dropside cargo trucks with winch, M926 and M926A1 cargo trucks with winch, M927 and M927A1 XLWB cargo trucks, M928 and M928A1 XLWB cargo trucks with winch, M929 and M929A1 dump trucks, M930 and M930A1 dump trucks with winch, M931 and M931A1 tractors, M932 and M932A1 tractors with winch, M934 and M934A1 expansible vans, M935 and M935A1 expansible vans with liftgate, and the M936 and M936A1 medium wreckers. National stock numbers for both winch and non-winch configurations are listed on the title page. The Change 2 edition adds the M923A2, M925A2, M927A2, M928A2, M929A2, M930A2, M931A2, M932A2, M934A2, M935A2 and M936A2 variants to the coverage.

Who This M939 Series Maintenance Manual Is For

This is the direct support and general support level manual – the level of maintenance that takes components off the truck and rebuilds them. It is written for the wheeled vehicle repairman (MOS 63W) working in a unit or depot shop. If you are maintaining, rebuilding or restoring an M939 series 5-ton, this is the volume that covers everything behind the engine and transmission. Engine, transmission and the first seven chapters of general information are in Volume 1 (TM 9-2320-272-34-1).

Get the Complete DS/GS Reference for Your M939 Series Truck

With TM 9-2320-272-34-2 Volume 2 on hand you can pull and rebuild the transfer case, service the front and rear axles and differentials, overhaul the air compressor and brake valves, adjust Ross or Sheppard steering gear, replace cab and body panels, service the dump hoist and fifth wheel, work on the M936 wrecker crane and the M934/M935 van body, rebuild front and rear winches, and repair the transfer case or transmission PTO. Every procedure is written to the level of detail needed to actually do the job, with torque values, wear limits and adjustment specs given in the text and Appendix E. The manual is delivered as an instant PDF download after checkout – no shipping, no waiting. Open it on any phone, tablet or computer, print the pages you need for the shop, and keep the rest of the file as your permanent reference.