M939 Diesel Truck Service Manual (M939A2)

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 V INTRODUCTION l-l SERVICE AND TROUBLESHOOTING INSTRUCTIONS 2-l PREVENTlVE MAINTENANCE CHECKS AND SERVICES (PMCS) 2-2 UNIT TROUBLESHOOTING 2-60 UNIT MAINTENANCE 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

TM 9-2320-272-24-1 WARNING EXHAUST GASES CAN KILL 1. DO NOT operate vehicle engine in enclosed area. 2 DO NOT idle vehicle engine with windows closed. 3. DO NOT drive vehicle with inspection plates or cover plates removed. 4. BE ALERT at all times for odors. 5. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness Loss of muscular control 6. IF YOU SEE another person with exhaust poisoning symptoms: Remove person from area Expose to open air Keep person warm Do not permit person to move Administer artificial respiration or CPR, if necessary* * For artificial respiration, refer to FM 21-11. 7. BE AWARE: The field protective mask for Nuclear, Biological, or Chemical (NBC) protection will not protect you from carbon monoxide poisoning. THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION. Warning a

TM 9-2320-272-24-1 WARNING SUMMARY Hearing protection is required for the driver and passenger. Hearing protection is also required for all personnel working in and around this vehicle while the engine is running (AR-40-5 and TB MED 501). If required to remain inside vehicle during extreme heat, occupants should follow the water intake, work/rest cycle, and other stress preventive measures (FM 21-10, Field Hygiene and Sanitation). If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment. Consult with your unit NBC officer or NBC NC0 for appropriate handling or disposal instructions. This vehicle has been designed to operate safely and efficiently within the limits specified in this TM. Operation beyond these limits is prohibited by IAW AR 70-l without written approval from the commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMCPEO-CM-S, Warren, MI 48397-5000. Never work under dump body unless safety braces are properly positioned. Failure to do this will result in injury to personnel. During winching operation, never stand between vehicles. Assistant must remain in secondary vehicle to engage service brake if cable snaps or automatic brake fails while towing vehicle. Failure to do this may result in injury to personnel. Accidental or intentional introduction of liquid contaminants into the environment is in violation of state, federal, and military regulations. Refer to Army POL (para. l-7) for information concerning storage, use, and disposal of these liquids. Failure to do so may result in injury or death. Cleaning solvents are flammable and toxic. Do not use near open flame and always have a fire extinguisher nearby when solvents are used. Use only in well-ventilated places, wear protective clothing, and dispose of cleaning rags in approved container. Failure to do this will result in injury to personnel and/or damage to equipment. Eyeshields must be worn when cleaning with compressed air. Compressed air source will not exceed 30 psi (207 kPa). Failure to do so may result in injury to personnel. Extreme care should be taken when removing surge tank filler cap if temperature gauge reads above 175°F (79°C). Steam or hot coolant under pressure will cause injury. Alcohol used in the alcohol evaporator is flammable, poisonous, and explosive. Do not smoke when removing alcohol evaporator or adding fluid, and do not drink fluid. Failure to do this will result in injury or death. Do not perform electrical circuit testing fuel tank with fill cap or sending unit removed. Fuel may ignite, causing injury to personnel. When performing battery maintenance, ensure batteries are seated and clamped down, all rubber boots are installed, clamps are well down on battery posts, and all battery cables lie flat against the top of the batteries. Failure to do this may result in injury to personnel and/or damage to equipment. Ensure companion seatbelts are not caught inside battery box. This will cause belts to rot which may lead to iujury of personnel. On M938/Al/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 result in injury to personnel or damage to equipment. Never assemble or disassemble tire and rim assembly while inflated, use inflation to seat lockring on split rim or tire on two-piece rim, or inflate a tire without a tire inflation cage. Injury to personnel may result. Do not disconnect air lines or hoses, remove safety valves or CTIS components, or perform brake chamber repairs before draining air reservoirs. Small parts under pressure may shoot out with high velocity, causing injury to personnel. Warning b

TM 9-2320-272-24-1 WARNlNG SUMMARY (Contd) Remove all jewelry when working on electrical circuits. Jewelry coming in contact with electrical circuits may produce a short circuit, causing extreme heat, explosions, and fling particles of metal. Failure to do so will result in injury or death and damage to equipment. Use eyeshields and follow instructions carefully when performing assembling, disassembling, or maintenance on this device. Components of this device are under spring tension and may shoot out at a high velocity. Failure to do so will result in injury to personnel. Do not remove hoses with engine running or start engine with hoses removed. High-pressure fluids may cause hoses to whip violently and spray randomly. Failure to do so may result in injury to personnel. Keep hands out from between metal surfaces when removing heavy components. Failure to do so may result in injury to personnel. Keep personnel out from under equipment and components of equipment when supported by only a lifting device. Sudden loss of lifting power or shift in load may result in injury or death. Do not drain engine, transmission, or radiator fluids, or remove lines containing these fluids, when hot. Doing so may result in injury to personnel. Vehicle will become charged with electricity if it contacts or breaks high-voltage wires. Do not leave vehicle while high-voltage lines are in contact with vehicle. Failure to do so may result in injury to personnel. Wear hand protection when handling lifting and winching cables, hot exhaust components, and parts with sharp edges. Failure to do so may result in injury to personnel. Do not perform fuel system procedures while smoking or within 50 ft (15.2 m) of sparks or open flame. Diesel fuel is highly flammable and can explode easily, causing injury or death to personnel and/or damage to equipment. Ensure drainvalve on aftercooler is open when filling cooling system. Failure to do so may result in injury to personnel. Turbocharger intake fins are extremely sharp and turn at very high rpm. Keep hands and loose items away from intake openings. Failure to do so may result in injury to personnel. Do not place hands between frame and radiator when removing screws from trunnion or lifting radiator. Sudden changes in support may cause the radiator to shift, causing injury to personnel. Air pressure may create airborne debris. Use eye protection or injury to personnel may result. Air system components are subject to high pressure. Always relieve pressure before loosening or removing air system components. Wear safety goggles when using a hammer. Ether is extremely flammable. Do not perform ether start system procedures near fire. Injury to personnel may result. Warning c/(Warning d blank)

ARMY TM 9-2320-272-24-l AIR FORCE TO 36A12-1C-1155-2-l TECHNICAL MANUAL NO. 9-2320-272-24-1 TECHNICAL ORDER NO. 36A12-1C-1155-2-1 HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE Washington,D.C., 30 JUNE 1998 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 NSN WITH 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 BTQ BTB BS4 BTR BTF BS6 BTT 2320-01-050-2084 2320-01-206-4087 2320-01-230-0307 2320-01-047-8771 2320-01-206-4089 2320-01-230-0309 2320-01-047-8769 2320-01-206-4088 2320-01-230-0308 2320-01-047-8756 2320-01-206-4079 2320-01-230-0305 2320-01-047-8770 2320-01-206-4090 2320-01-230-0310 2320-01-047-8753 2320-01-206-4077 2320-01-230-0302 2320-01-047-8755 2320-01-206-4080 2320-01-230-0306 2320-01-047-8750 2320-01-205-2682 2320-01-230-0300 2320-01-047-8752 2320-01-205-2684 2320-01-230-0303 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. CHAPTER 1 Section I. Section II. Section III. CHAPTER 2 Section I. Section II. Section III. Section IV. CHAPTER 3 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. TABLE OF CONTENTS VOLUME 1 OF 4 HOW TO USE THIS MANUAL Page ........................................ v INTRODUCTION ................................................... l-l General Information ....................................................... l-l Equipment Description and Data ............................................ l-5 Principles of Operation ..................................................... l-25 SERVICE AND TROUBLESHOOTING INSTRUCTIONS .................. 2-l Repair Parts; Tools; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment ...................... 2-l ServiceUponReceipt ...................................................... 2-l PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) ........ 2-2 UNIT TROUBLESHOOTING PROCEDURES ........................... 2-60 UNIT MAINTENANCE .............................................. 3-l Engine System Maintenance ................................................ 3-l Air Intake System Maintenance ............................................. 3-41 Fuel System Maintenance .................................................. 3-55 Exhaust System Maintenance ............................................... 3-139 Cooling System Maintenance ................................................ 3-149 Electrical System Maintenance .............................................. 3-220 Transmission and Transfer Case Maintenance .................................. 3-353 Propeller Shafts, Axles, and Suspension System Maintenance ..................... 3-403 Compressed Air and Brake System Maintenance ................................ 3-476 Wheels, Hubs, Drums, and Steering Maintenance ............................... 3-615 Frame Maintenance ....................................................... 3-683 Body, Cab, and Accessories Maintenance ...................................... 3-730 Winch and Power Takeoff (PTO) Maintenance .................................. 3-823 Special Purpose Bodies Maintenance ......................................... 3-869 Special Purpose Kits ....................................................... 3-968 Central Tire Inflation System (CTIS) Maintenance .............................. 3-1231 ii

TM 9-2320-272-24-1 TABLE OF CONTENTS (Contd) 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. Page DIRECT SUPPORT (DS) MAINTENANCE .............................. 4-l Direct Support (DS) and General Support (GS) Mechanical Troubleshooting .......... 4-1 Power Plant Maintenance .................................................. 4-35 Engine (M939lAl) Maintenance ............................................. 4-117 Engine (M939A2) Maintenance .............................................. 4-271 Cooling System Maintenance ................................................ 4-352 Electrical System Maintenance .............................................. 4-388 TransmissionMaintenance ................................................. 4-465 Transfer Case Maintenance ................................................. 4-504 Front and Rear Axle Maintenance ............................................ 4-548 Compressed Air and Brake System ........................................... 4-584 Power Steering System Maintenance ......................................... 4-605 Frame Maintenance ....................................................... 4-681 Body, Cab, and Hood Maintenance ........................................... 4-691 Special Purpose Bodies Maintenance ......................................... 4-715 Winch, Hoist, and Power Takeoff (PTO) Maintenance ............................ 4-808 Special Purpose Kits Maintenance ........................................... 4-1002 CHAPTER 5 GENERAL SUPPORT (GS) MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . 5-l Section I. Engine (M939/Al) Maintenance ............................................. 5-l Section II. Engine (M939A2) Maintenance ............................................. 5-157 Section III. Transmission Maintenance ................................................. 5-280 Section IV. Transfer Case Maintenance ................................................. 5-398 Section V. Front and Rear Axle Maintenance ............................................ 5432 Section VI. Special Purpose Bodies Maintenance ......................................... 5-463 Section VII. Winch, Hoist, and Power Takeoff (PTO) Maintenance ............................ 5-606 CHAPTER 6 SHIPMENT AND LIMITED STORAGE INSTRUCTIONS ................. 6-l Section I. General Preparation of Vehicle for Shipment ................................... 6-l Section II. LoadingandMovement .................................................... 6-2 Section III. Limited Storage .......................................................... 6-2 APPENDIX A APPENDIX B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-l MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-l Section I. Introduction ............................................................. B-l Section II. Maintenance Allocation Chart ............................................... B-4 Section III. Tool and Test Equipment Requirements ....................................... B-25 Section IV Remarks ................................................................ B-26 REFERENCES APPENDIX C Section I. Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ............ C-l Introduction ............................................................. C-l Expendable/Durable Supplies and Materials List ................................ C-3 APPENDIX D MANDATORY REPLACEMENT PARTS ............................... D-l iii

TM 9-2320-272-24-1 APPENDIX E COMMON AND SPECIAL TOOL IDENTIFICATION LIST . . . . . . . . . . . . . . . . E-l APPENDIX F ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . ....... F-l APPENDIX G TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-l APPENDIX H SCHEMATIC AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 iv

TM 9-2320-272-24-l HOW TO USE THIS MANUAL ABOUT YOUR MANUAL Spend some time looking through this manual. You’ll find that it has a new look, different than most TMs you’ve 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 Here’s 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. Look at the cover of this manual. You’ll see subjects listed from top to bottom on the right-hand side. 2. Look at the right edge of the manual. On some of the pages you’ll 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. Look for UNIT TROUBLESHOOTING in the subject list on the cover, 4. 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. 5. 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. 6. 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. 7. Turn to the page indicated: page 2-9. 8. 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. 9. 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. v

M939 Diesel Truck Service Manual (M939A2)

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