Truck 5 Ton M939 Series Diesel Service Repair Manual
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🏷️ Basic Information
Identification
Make:
AM General
Model:
M939 Series (and variants)
Codes
Chassis Codes:
M923, M923A1, M924, M924A1, M925, M925A1, M926, M926A1, M927, M927A1, M928, M928A1, M929, M929A1, M930, M930A1, M931, M931A1, M932, M932A1, M934, M934A1, M935, M935A1, M936, M9361
👋 Introduction
Market Position
Target Audience:
Military vehicle mechanics, fleet maintenance personnel, civilian operators of M939 series trucks
Key Features
Documentation Origin:
Public domain U.S. Government manual, not copied from other CD-ROM products
File Size And Organization:
60MB file, consolidating 4 volumes into a single searchable PDF
📋 Manual Details
Coverage Areas
Primary Coverage:
Unit Maintenance (Preventive Maintenance Checks & Services, Troubleshooting, Systems Maintenance & Repair)
Page Count
Total Pages:
3600+
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF (4 volumes in 1)
📖 Manual Coverage
Systems Covered
Mechanical Systems:
Engine, Transmission, Drivetrain (Propeller Shafts, Axles), Suspension, Brakes, Steering, Cooling, Fuel, Exhaust, Air Intake
Electrical Systems:
Wiring Diagrams, Lighting, Starting System, Charging System, Instrumentation, Control Systems
Procedures Included
Maintenance Procedures:
Preventive Maintenance Checks and Services (PMCS), Lubrication Schedules, Fluid Level Checks, Filter Replacements
Troubleshooting Procedures:
Mechanical Systems Troubleshooting, Electrical Systems Troubleshooting, Diagnostic Flowcharts
Repair Procedures:
Component Removal and Installation, Overhaul Procedures, Adjustments, Calibration
Technical Depth
Depth:
Comprehensive unit maintenance and repair, suitable for field service and workshop personnel
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Illustrations:
Numerous high-quality illustrations, line drawings, and exploded views
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Model M939 M939A1:
Cummins NHC-250
Engine Model M939A2:
Cummins 6CTA8.3 Turbo-Diesel
Performance
Displacement Nhc 250:
14 Liters
Configuration Nhc 250:
Inline 6-Cylinder Diesel
Fuel System
Fuel Type:
Diesel
Maintenance
Recommended Oil Type:
Refer to manual for specific API service categories and viscosity grades (e.g., SAE 15W-40 for diesel engines)
🔧 Transmission
Standard
Transmission Type:
Allison Automatic
Features
Number Of Speeds:
5-Speed Automatic with 2-Speed Transfer Case
Maintenance
Transmission Fluid Type:
Allison TES-295 approved fluids (e.g., Dexron III/Mercon or equivalent)
📐 Dimensions
Exterior
Length M939A2:
7,890 mm (310.6 inches)
Width M939A2:
2,470 mm (97.2 inches)
Height M939A2:
3,070 mm (120.9 inches)
Weights
Curb Weight M939A2:
9,027 kg (19,901.1 lbs)
Chassis
Drive Layout:
6x6 All-Wheel Drive
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Military Vehicle - Not subject to civilian crash testing standards)
Active Features
Braking System:
Air Brakes (Service and Parking)
Passive Features
Cab Construction:
Heavy-duty steel construction designed for extreme environments and load-bearing
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation for operational monitoring (e.g., speedometer, tachometer, engine vitals, warning lights). No modern infotainment features.
Driver Assistance
Driver Assistance Features:
None. Designed for raw utility and operational capability, not modern driver assistance.
Connectivity
Connectivity Options:
None. Military communication systems may be integrated separately.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual; typically based on mileage or operating hours (e.g., 3,000-5,000 miles or 250 hours)
Transmission Fluid Service:
Refer to manual; typically based on mileage or operating hours and operating conditions (e.g., 20,000-50,000 miles)
Fluid Specifications
Engine Coolant:
Ethylene Glycol based coolant, typically 50/50 mix with distilled water. Specific type (e.g., heavy-duty diesel coolant) and additive requirements are detailed in the manual.
Differential And Axle Fluid:
GL-5 rated gear oil, appropriate viscosity (e.g., 80W-90 or 85W-140) depending on ambient temperature. Refer to manual for exact specifications and capacities.
Known Issues
Common Wear Items:
Brake components (shoes, drums, air lines), suspension bushings, universal joints, exhaust system components, cooling system hoses and radiators, engine accessory belts and hoses.
Troubleshooting Tips
Engine Starting Issues:
Check battery charge, glow plug operation, fuel system integrity, air intake restrictions, and starter motor engagement.
Transmission Shifting Issues:
Verify transmission fluid level and condition, check for air leaks in the pneumatic control system, and diagnose solenoid or hydraulic issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
AM General (initial production), BMY (later production and M939A2 variants)
Model Evolution
Series Development:
Successor to the M35 series, designed for increased payload and improved performance
Production
Production Start:
1982
Production Update:
M939A1 series updated variants, M939A2 series production began 1989
🏆 Awards & Recognition
Recognitions
Military Service:
Widely adopted and deployed by the United States Armed Forces and allied nations due to its robustness and versatility.
Mechanical Systems Troubleshooting, Electrical Systems Troubleshooting, Diagnostic Flowcharts
Repair Procedures:
Component Removal and Installation, Overhaul Procedures, Adjustments, Calibration
Technical Depth
Depth:
Comprehensive unit maintenance and repair, suitable for field service and workshop personnel
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Illustrations:
Numerous high-quality illustrations, line drawings, and exploded views
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Model M939 M939A1:
Cummins NHC-250
Engine Model M939A2:
Cummins 6CTA8.3 Turbo-Diesel
Performance
Displacement Nhc 250:
14 Liters
Configuration Nhc 250:
Inline 6-Cylinder Diesel
Fuel System
Fuel Type:
Diesel
Maintenance
Recommended Oil Type:
Refer to manual for specific API service categories and viscosity grades (e.g., SAE 15W-40 for diesel engines)
🔧 Transmission
Standard
Transmission Type:
Allison Automatic
Features
Number Of Speeds:
5-Speed Automatic with 2-Speed Transfer Case
Maintenance
Transmission Fluid Type:
Allison TES-295 approved fluids (e.g., Dexron III/Mercon or equivalent)
📐 Dimensions
Exterior
Length M939A2:
7,890 mm (310.6 inches)
Width M939A2:
2,470 mm (97.2 inches)
Height M939A2:
3,070 mm (120.9 inches)
Weights
Curb Weight M939A2:
9,027 kg (19,901.1 lbs)
Chassis
Drive Layout:
6x6 All-Wheel Drive
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Military Vehicle - Not subject to civilian crash testing standards)
Active Features
Braking System:
Air Brakes (Service and Parking)
Passive Features
Cab Construction:
Heavy-duty steel construction designed for extreme environments and load-bearing
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation for operational monitoring (e.g., speedometer, tachometer, engine vitals, warning lights). No modern infotainment features.
Driver Assistance
Driver Assistance Features:
None. Designed for raw utility and operational capability, not modern driver assistance.
Connectivity
Connectivity Options:
None. Military communication systems may be integrated separately.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Refer to manual; typically based on mileage or operating hours (e.g., 3,000-5,000 miles or 250 hours)
Transmission Fluid Service:
Refer to manual; typically based on mileage or operating hours and operating conditions (e.g., 20,000-50,000 miles)
Fluid Specifications
Engine Coolant:
Ethylene Glycol based coolant, typically 50/50 mix with distilled water. Specific type (e.g., heavy-duty diesel coolant) and additive requirements are detailed in the manual.
Differential And Axle Fluid:
GL-5 rated gear oil, appropriate viscosity (e.g., 80W-90 or 85W-140) depending on ambient temperature. Refer to manual for exact specifications and capacities.
Known Issues
Common Wear Items:
Brake components (shoes, drums, air lines), suspension bushings, universal joints, exhaust system components, cooling system hoses and radiators, engine accessory belts and hoses.
Troubleshooting Tips
Engine Starting Issues:
Check battery charge, glow plug operation, fuel system integrity, air intake restrictions, and starter motor engagement.
Transmission Shifting Issues:
Verify transmission fluid level and condition, check for air leaks in the pneumatic control system, and diagnose solenoid or hydraulic issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
AM General (initial production), BMY (later production and M939A2 variants)
Model Evolution
Series Development:
Successor to the M35 series, designed for increased payload and improved performance
Production
Production Start:
1982
Production Update:
M939A1 series updated variants, M939A2 series production began 1989
🏆 Awards & Recognition
Recognitions
Military Service:
Widely adopted and deployed by the United States Armed Forces and allied nations due to its robustness and versatility.
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