1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1
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Volume 1 of the 1992 direct support and general support Repair Parts and Special Tools List for 5-ton, 6×6 M809 Series diesel trucks. Covers illustrated repair parts, model-specific usable-on codes, special tools, NSN and part-number references, and major vehicle systems from the Cummins NHC 250 engine through chassis, body, winch, crane and power takeoff components.
Description
1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1
This 1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1 is the direct support and general support maintenance repair-parts reference for the M809 Series diesel truck family. Published by Headquarters, Department of the Army in January 1992 and current as of July 1991, it organizes illustrated parts information by vehicle system and identifies the components, assemblies, repair kits, special tools, test equipment and support items used for maintenance. The manual is especially useful when you need to identify a component from an illustration, confirm its part number or National Stock Number, check the applicable model through a usable-on code, or determine the maintenance and recoverability information carried by the SMR code.
File Details
- Manual type: Direct Support and General Support Maintenance Repair Parts and Special Tools List
- Series: M809 Series 5-ton, 6×6 diesel trucks
- Technical manual: TM 9-2320-260-34P-1
- Air Force technical order: TO 36A12-1C-382-1
- Volume: Volume 1 of 2
- Date: 15 January 1992; current as of July 1991
- Language: English
- Page count: 1028 PDF pages
- File format: PDF
Truck Models Covered
The M809 Series parts and special tools manual covers a broad group of 5-ton 6×6 truck configurations. Models identified in the publication include M810, M812A1, M813, M813A1, M814, M815, M816, M817, M818, M819, M820, M820A1, M820A2 and M821. The manual distinguishes applicable configurations through usable-on codes, including with-winch and without-winch versions where listed. This matters because many assemblies and line items are shared across the series while others apply only to a particular body, drivetrain, fuel-system, wrecker, van, tractor or winch configuration.
The engine section identifies the diesel engine as the Cummins NHC 250. Throughout the parts listings, individual entries can also carry serial-number conditions such as use before or after a stated serial number. Those applicability notes are printed with the affected item rather than being treated as one blanket serial range for the entire M809 Series.
How the Parts Information Is Organized
TM 9-2320-260-34P-1 is built around illustrated figures followed by corresponding itemized parts lists. Each listing can identify the item number, SMR code, CAGEC, part number, description and usable-on code, and quantity. The introduction explains how these columns are used and how the source, maintenance and recoverability positions of the SMR code indicate how an item is obtained, the maintenance level authorized to use or repair it, and the disposition of an unserviceable item.
The manual also explains the usable-on-code system for the different M809 Series models and configurations. Uncoded items are applicable to all models, while coded entries identify a narrower application. For someone working across several M809 variants, this is one of the most valuable parts of the reference because the same illustration can contain components for multiple truck configurations without treating every part as universally interchangeable.
IMAGES PREVIEW
Chapters Covered
- Introduction: scope of the Repair Parts and Special Tools List, organization of the sections, SMR codes, CAGEC and part-number fields, usable-on codes, associated publications and instructions for locating repair parts.
- Engine: engine and container assembly, engine mounts and lifting bracket, cylinder block and head, crankshaft, flywheel housing, pistons and connecting rods, timing components, camshaft, valve train, lubrication system, intake and exhaust manifolds, and accessory drive components.
- Clutch: clutch assembly, housing, release mechanism, linkage and pedal components.
- Fuel System: fuel injectors, fuel-pump assemblies, AFC and VS governor components, air cleaner, fuel filters, water separator, single and dual fuel tanks, supply/return/vent lines, cold-start equipment and accelerator controls.
- Exhaust System: vertical and horizontal exhaust-system components.
- Cooling System: radiator hoses and radiator assembly, surge tank, shrouds and baffles, thermostat and water manifold, air-compressor coolant lines, water pump, fan, hubs and belts.
- Electrical System: alternator, starter, instrument panel and cluster, circuit breakers, protective control equipment, vehicle lighting, blackout lamps, warning devices, transmitters, horn, batteries, slave receptacle and wiring harness assemblies.
- Transmission: transmission and container assembly, case components, synchronizers, input and output shafts, countershaft, gears, shifter housing, shafts, forks, valves and gearshift lever.
- Transfer Case: transfer assembly and mounting, covers and seals, clutch and input shaft, housing and access plates, intermediate and output shafts, bearings, shift mechanism, declutch piping and controls.
- Propeller Shafts: driveline shaft assemblies between the transmission, transfer, center bearing, front axle and rear axle combinations.
- Front Axle: axle and housing assembly, differential, carrier, through-shaft and gear components, drive pinion, spindle, universal shaft and steering-knuckle related parts.
- Rear Axle: rear axle and housing assembly, differential, carrier, access covers, through-shaft, gears, flanges and drive-pinion components.
- Brakes: parking brake, front and rear service brakes, hydraulic lines, air pack and cylinder, master and wheel cylinders, brake pedal and linkage, service and emergency air lines, reservoirs, compressor, governor and trailer-brake equipment.
- Wheels: wheel assemblies, front and rear hubs and drums, hub conversion parts, tires and tubes.
- Steering: steering column and wheel, propeller shaft, drag link, Pitman arm, cross-shaft, tie rods, steering gear, power-steering pump, hydraulic lines and steering cylinder.
- Frame and Towing Attachments: frame assemblies for the various bodies, vehicle tiedowns, bumpers, lifting shackles, field chocks, pintle hook, towing brackets, spare-tire carriers and fifth-wheel components.
- Springs and Shock Absorbers: front and rear leaf springs, mounting hardware, shock absorbers and torque rods.
- Body, Cab and Hood: hood and brush-guard components, cab assembly, doors, windows and windshield, fenders, running boards, seats, tool boxes, cargo bodies, side racks, troop seats, dump body and related body hardware included in this volume.
- Hoist, Winch, Crane and Power Takeoff: front winch, bolster-logger midwinch, wrecker rear winch, dump hydraulic hoist, wrecker crane assemblies, boom and cylinders, hydraulic lines and tank, tractor-wrecker crane components, van liftgate, PTO and power-divider components and controls.
- Body, Chassis and Accessory Items: soft top, wipers, mirrors, reflectors and identification/data plates for vehicle systems and special equipment.
- Special Purpose Kits: personnel and coolant heater kits, deep-water fording equipment, hardtop and thermal-barrier items, seat-belt and mud-flap kits, electrical and lighting kits, vehicle tiedown equipment and other listed modification/support kits.
- Non-Electrical Gages: tachometer, speedometer, air-pressure and oil-pressure indicators.
- Repair Parts Kits and Standardized Parts: repair-parts kits and general-use standardized bulk items.
- Special Tools List: organizational, direct-support and general-support tool kits, together with tools, TMDE and other special support equipment authorized in the publication.
- Cross-Reference Indexes: National Stock Number index, part-number index, and figure-and-item-number index for tracing a known number back to the illustrated parts listing.
Taken together, these sections make the 1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1 a large component-identification and parts-requisition reference rather than a short service booklet. The illustrations let you work from an assembly view to an item number, while the adjacent listing supplies the identifiers and applicability information needed to distinguish parts. The index sections provide the reverse route when you already have an NSN or part number and need to locate the figure and item in which it appears.
Illustrated Assemblies and Model-Specific Detail
The repair-parts section contains extensive line drawings and exploded assembly views. Early figures alone cover the engine and container assembly, engine mounts, cylinder block, cylinder head, crankshaft and bearings, piston and rod assembly, timing gear cover, camshaft, rocker gear, lubrication components, clutch, fuel-injection parts and fuel-pump assemblies. The same illustrated-parts approach continues through the remaining vehicle systems. This format is useful when a part name or number is not known: the manual instructs the reader to find the applicable assembly group, locate the figure, identify the item visually, and then use the figure and item reference to find the corresponding stock information.
Complete Bookmarks
The complete bookmarks in the “1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1” are as follows:
+GROUPS
+FIGURES
+SECTIONSp. 1
+PAGES
When a National Stock Number or part number is already known, the cross-reference indexes point back to the relevant illustration and item. CAGEC information identifies the manufacturer, distributor or government activity associated with an item, while the description column can carry kit relationships, fabrication references, effective serial information and usable-on codes. The result is a parts catalog that supports both visual identification and number-based lookup across a complicated family of M809 Series vehicles.
Important Use of This Manual
This volume is a Repair Parts and Special Tools List. Its strength is component identification, application, requisitioning references, parts breakdowns and tool authorization for direct and general support maintenance. It is not a substitute for the step-by-step maintenance procedures contained in the associated M809 Series maintenance manuals. The publication itself points readers to manuals including TM 9-2320-260-20 and TM 9-2320-260-34 for maintenance and assembly instructions. For restoration, workshop, fleet-support or parts-sourcing work, using the parts list together with the applicable maintenance manual gives a much clearer path from identifying a failed assembly to selecting the correct component and then carrying out the repair procedure.
Get the M809 Series Parts Reference Instantly
The 1992 M809 Series 5-Ton 6×6 Diesel Truck Repair Parts & Special Tools Manual Volume 1 – TM 9-2320-260-34P-1 helps you identify repair parts, compare model applicability, trace NSNs and part numbers, interpret illustrated assemblies and locate the special tools associated with direct and general support maintenance. Correct part identification and usable-on-code checking are especially important on a truck family with numerous chassis, cargo, dump, tractor, van, wrecker and winch configurations, because an apparently similar component may have a different application.
Purchase gives you instant PDF delivery with no shipping to wait for. Open the manual on a computer, tablet or phone with a PDF reader, keep it available beside the vehicle or parts inventory, and print the pages you need for workshop reference.
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