TM 9-2320-260-20 M809 Series 5-Ton Truck Unit Maintenance Manual – PDF

Description

Official U.S. Army Unit Maintenance Manual for the 5-Ton, 6×6 M809 Series Diesel Trucks

This is the complete, official TM 9-2320-260-20 technical manual, providing unit-level maintenance procedures for the entire M809 series of tactical trucks. This is the direct replacement for all earlier 20-level manuals (TM 9-2320-260-20-1, -2-1, -3-1, etc.) dated January 1981. It consolidates and supersedes those publications into a single, authoritative document for all M809 models.

This manual is the primary source for troubleshooting, repair, and replacement of components at the unit maintenance level. It is a comprehensive guide to keeping these critical military vehicles operational, covering everything from scheduled preventive maintenance to complex system repairs.

File Details

• Manual Type: Unit Maintenance Technical Manual
• Document Number: TM 9-2320-260-20
• Supersedes: TM 9-2320-260-20-1, TM 9-2320-260-20-2-1, TM 9-2320-260-20-3-1, TM 9-2320-260-20-2-2, TM 9-2320-260-20-3-3, and TM 9-2320-260-20-3-4 (dated 12 January 1981)
• Date of Issue: 28 April 1995
• Language: English
• Page Count: 1,336 Pages
• Format: PDF

Chapters Covered

This manual is divided into 15 chapters, covering every major system on the M809 series trucks:

• Chapter 1: Introduction – Scope, equipment description, data, principles of operation (control, power, electrical, compressed air, air-hydraulic brake, and special purpose bodies).
• Chapter 2: Service and Troubleshooting Instructions – PMCS, mechanical systems troubleshooting, compressed air and air-hydraulic brake system troubleshooting, electrical systems troubleshooting, and STE/ICE troubleshooting.
• Chapter 3: Engine Systems Maintenance – Lubrication system, clutch system, air intake system, fuel system, accelerator system, exhaust system, and cooling system maintenance.
• Chapter 4: Electrical System Maintenance – Charging system, starting system, instruments, sending units, switches, horn, lighting system, battery system, and wiring circuits/harness maintenance.
• Chapter 5: Transmission Maintenance – Covers the Dana 6453 manual transmission, including breather maintenance.
• Chapter 6: Transfer Case System Maintenance – Transfer case declutch piping, shift lever and control linkage, and breather maintenance.
• Chapter 7: Propeller Shafts, Axles, and Suspension System Maintenance – Includes propeller shaft repair, universal joint maintenance, front and rear axle maintenance, and front/rear suspension maintenance.
• Chapter 8: Mechanical Parking Brake, Compressed Air, and Service Brake System Maintenance – In-depth coverage of parking brakes, service brakes, hydraulic system, air reservoirs, governor, and related components.
• Chapter 9: Wheels, Hubs, Drums, and Steering System Maintenance – Jacking procedures, wheel/tire maintenance, hub and drum maintenance, wheel bearing adjustment, and complete steering system maintenance.
• Chapter 10: Frame Maintenance – Covers lifting shackles, bumper, pintle hook, fifth wheel replacements, and more.
• Chapter 11: Body, Cab, and Accessories Maintenance – Hood, fenders, cab doors, mirrors, windshield wipers, seats, and more.
• Chapter 12: Special Purpose Bodies Maintenance – Detailed sections for Cargo, Dump, Van, Wrecker, Tractor Wrecker, and Bolster bodies.
• Chapter 13: Hoist, Winch, and Crane Maintenance – Comprehensive coverage of front, midship, and rear winches, dump hoist, and wrecker crane systems.
• Chapter 14: Special Purpose Kits Maintenance – Winterization kits, deepwater fording, A-frame kit, machine gun mounts, min lighting, and more.
• Chapter 15: Shipment and Limited Storage – Procedures for preserving, packaging, and storing the vehicle.

In addition, the manual includes four detailed appendices: References, Maintenance Allocation Chart (MAC), Expendable/Durable Supplies and Materials List, Torque Limits, and Schematic & Wiring Diagrams.

What This Manual Enables You to Do

This is not a simple owner’s handbook. It is a professional-grade maintenance manual designed for military unit mechanics. With this PDF, you can perform a complete range of service tasks on any M809 series truck. From troubleshooting a no-start condition to rebuilding a winch brake or adjusting a transmission linkage, this manual provides the step-by-step procedures, torque values, and specifications required.

Key capabilities include:

• Diagnostics: Use the extensive troubleshooting charts in Chapter 2 to quickly isolate mechanical, electrical, and air system faults.
• Scheduled Maintenance: Follow the comprehensive PMCS (Preventive Maintenance Checks and Services) tables to keep the vehicle in top condition and prevent failures.
• Complete System Repairs: Disassemble and reassemble major assemblies, including the engine, transmission, transfer case, axles, and brake systems, with confidence.
• Winch and Crane Service: Maintain and repair the front, rear, and midship winches, as well as the wrecker crane’s hydraulic system.
• Body and Frame Work: Address issues with the cab, cargo bed, dump body, van body, and frame attachments.

Having the correct procedures and specifications is critical for effective and safe repairs. This official manual ensures you have the exact data the engineers intended, preventing costly guesswork and damage from incorrect repair methods.

Please note: This manual is a unit-level publication. It covers maintenance tasks that can be performed at the unit level with available tools and resources. More in-depth overhauls (e.g., engine rebuilds, transmission overhauls) are referenced to Direct Support or Depot-level publications where appropriate.

Instant Download

This is a digital download. After payment, you will receive immediate access to the complete PDF file. No shipping costs, no waiting. Use it on your computer, tablet, or print specific sections for use in the workshop. This is the single most comprehensive reference you can own for the M809 series 5-ton truck.