U.S. Army M809 Series 5-Ton 6×6 Repair Parts & Special Tools Manual Vol. 1 – TM 9-2320-260-24P-1

Description

U.S. Army M809 Series 5-Ton 6×6 Repair Parts & Special Tools Manual Vol. 1

This U.S. Army M809 Series 5-Ton 6×6 Repair Parts & Special Tools Manual Vol. 1 – TM 9-2320-260-24P-1 is the unit, direct support, and general support maintenance Repair Parts and Special Tools List for the diesel M809 Series truck family. Issued by the Departments of the Army and the Air Force, this first volume is built around illustrated component breakdowns and detailed parts listings that support identification, requisitioning, replacement planning, and maintenance logistics across numerous M809-series configurations.

File Details

• Manual type: Unit, Direct Support, and General Support Maintenance Repair Parts and Special Tools List
• Vehicle family: Truck, 5-Ton, 6×6, M809 Series (Diesel)
• Models covered: M810, M812A1, M813, M813A1, M814, M815, M816, M817, M818, M820, M820A1, M820A2, M821
• Engine identified: Cummins NHC 250 diesel
• Technical manual: TM 9-2320-260-24P-1
• Air Force technical order: TO 36A12-1C-382-1
• Volume: Volume 1 of 2
• Issue date: 30 September 2003
• Current as of: 22 March 2002
• Language: English
• Page count: 696 pages
• File format: PDF
• Work packages in this volume: 0001 00 through 0289 00

Vehicle Coverage

The M809 Series parts coverage is not limited to a single cargo truck. The manual identifies application differences using usable-on codes and organizes parts for a broad set of military 5-ton 6×6 configurations. Covered vehicles include M810 chassis trucks, M812A1 rocket-launcher chassis, M813 and M813A1 cargo trucks, M814 cargo trucks, M815 bolster-logging trucks, M816 medium wreckers, M817 dump trucks, M818 tractors, M820, M820A1, and M820A2 expansible vans, and the M821 stake bridge-transporting truck.

Usable-on codes distinguish many with-winch and without-winch applications, allowing a parts listing to show when an item belongs only to a particular configuration instead of treating every M809-series truck as identical. Some component listings also contain applicability information tied to component serial-number breakpoints, giving the reader a more precise basis for checking the correct listed item.

Illustrated Parts Identification

A major strength of TM 9-2320-260-24P-1 is its extensive sequence of illustrated assemblies. Figures break major systems into identifiable components, with numbered callouts tied directly to the accompanying repair-parts list. Examples range from the Cummins NHC 250 engine and cylinder block to crankshaft bearings, pistons, valve train, fuel-system components, clutch assemblies, transmission parts, axles, brake equipment, steering components, frames, cab parts, cargo bodies, and dump-body hardware.

The accompanying columns provide the information needed to move from a visual component to its supply identity. Depending on the entry, this includes NSN, CAGEC, manufacturer or government part number, item description, UOC, quantity, and SMR code. The introduction also explains how those SMR positions indicate how an item is obtained, which maintenance level may remove or replace it, the level capable of complete repair, and the disposition of an unserviceable item.

IMAGES PREVIEW

Chapters Covered

• Introduction: RPSTL scope, SMR codes, repair-parts-list columns, usable-on codes, cross-reference methods, and procedures for locating repair parts.
• Group 01 – Engine: engine and container assembly; engine mounts and lifting bracket; cylinder block and cylinder head; crankshaft, flywheel, pistons and connecting rods; camshaft and timing components; valve train and rocker assemblies; lubrication system; oil pump, filter, pan and cooler; intake and exhaust manifolds; accessory drive components.
• Group 02 – Clutch: clutch assembly, housing, related parts, linkage, release mechanism, and pedal components.
• Group 03 – Fuel System: fuel injectors; AFC and VS fuel-pump assemblies; governors and pump components; air cleaner; fuel tanks; tank mounting; vent, supply, return and crossover lines; selector valve; filters; cold-start equipment; accelerator controls and linkage.
• Group 04 – Exhaust System: vertical and horizontal exhaust-system assemblies.
• Group 05 – Cooling System: radiator and hoses; surge tank; fan shroud and baffles; thermostat; water manifold; air-compressor coolant lines; water pump; fan, hub and belts.
• Group 06 – Electrical System: alternator and starter; instrument-panel switches and cluster; circuit breakers; lighting and blackout-light components; warning systems; horn; batteries and cables; slave receptacle; front, rear, accessory and intervehicular wiring harnesses for multiple truck configurations.
• Group 07 – Transmission: transmission assembly and case; synchronizers; input and output shafts; countershaft, idler shaft and gears; shifter housing, shafts, forks and controls.
• Group 08 – Transfer Case: transfer assembly and mounting; covers and seals; clutch and input shaft; intermediate and output shafts; shift mechanisms, declutch piping and controls.
• Group 09 – Propeller Shafts: driveline assemblies between transmission, transfer, front axle and tandem rear axles, including center-bearing arrangements.
• Group 10 – Front Axle: axle and housing assemblies; differential; carrier; through-shaft and gears; drive pinion; spindle, universal shaft and steering-knuckle components.
• Group 11 – Rear Axle: rear axle housings and assemblies; differentials; carriers; through-shafts, gears, flanges and drive-pinion components.
• Group 12 – Brakes: parking brake; front and rear service brakes; hydraulic lines; air-pack assemblies; master and wheel cylinders; brake pedal and linkage; service and emergency air lines; reservoirs; air compressor and governor; trailer-brake controls and couplings.
• Group 13 – Wheels: wheel assemblies, front and rear hubs and drums, hub conversion components, tires and tubes.
• Group 14 – Steering: steering column and wheel; drag link and pitman arm; tie rods; steering gear; power-steering pump; hydraulic lines; steering and power-steering cylinders.
• Group 15 – Frame and Towing Attachments: frame assemblies for multiple body types; vehicle tiedowns; bumpers and shackles; field chocks; pintle hook and mounting brackets; spare-tire carriers; fifth-wheel assemblies and mounting parts.
• Group 16 – Springs and Shock Absorbers: front and rear leaf springs, mounting hardware, shock absorbers and torque rods.
• Group 18 – Body, Cab, and Hood: hood and guards; cab body and doors; windshield; fenders; running boards; seats; storage and tool-box equipment; cargo bodies and racks; troop seats; long-wheelbase body components; dump body, hoist mounting, tailgate controls and splash guards.

Taken together, the Volume 1 work packages provide a detailed parts-identification path from the engine through the driveline, chassis, brakes, steering, cab, cargo body and dump-body assemblies. The combination of drawings and structured parts columns is designed to help a maintainer identify an item first and then determine the corresponding supply information and vehicle applicability without relying on a component name alone.

NSN, Part Number, SMR and Usable-On Code Reference

The manual explains two practical ways to locate a repair part. When the NSN or part number is not known, the reader can start with the assembly or subassembly, locate its figure, identify the numbered item, and then use the parts listing. When an NSN or part number is already known, the RPSTL cross-reference structure provides the figure and item relationship needed to locate that component in the illustrated breakdown.

Usable-on codes are particularly important for this vehicle family because many assemblies differ between models and between with-winch and without-winch configurations. The parts tables preserve those distinctions rather than presenting every listed component as universally applicable. For maintenance and restoration work on an M809-series truck, that model-specific identification can be as important as the part number itself.

Parts Reference for M809 Series Maintenance

The U.S. Army M809 Series 5-Ton 6×6 Repair Parts & Special Tools Manual Vol. 1 – TM 9-2320-260-24P-1 gives technicians, restorers, fleet maintainers, and parts personnel a structured reference for identifying assemblies and the individual components used across the covered M809-series vehicles. It supports parts research for engine, fuel, cooling, electrical, transmission, transfer, axle, brake, steering, chassis, cab, cargo-body and dump-body work by connecting illustrated callouts with the corresponding supply and applicability data.

Using the correct figure, NSN, part number, SMR code and usable-on code helps reduce uncertainty when selecting components for a specific truck configuration and provides a more reliable basis for maintenance planning and parts requisitioning. This is an instant PDF download with no physical shipping required. The file can be viewed on compatible computers, tablets, and phones and printed when a paper reference is preferred.