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ARMY TM 9-2320-260-2AIR FORCE TO 36A12-1C-49

T h i s pub l i c a t i o n super sedes T M 9 - 2 3 2 0 - 2 6 0 - 2 0 - 1 ,

TM 9-2320-260-20-2-1, TM 9-2320-260-20-2-2,

TM 9-2320-260-20-3-1, TM 9-2320-260-20-3-2,

TM 9-2320-260-20-3-3, a nd TM 9-2320-260-20-3-4,

da ted 1 2 J a n ua r y 1 9 8 1, f o r M8 09 S er i es Tr uc ks .

T E C H N I C A L M A N U A L

U N I T M A I N T E N A N C E

5 - T O N , 6 X 6 ,

M 8 0 9 S E R I E S T R U C K S

( D I E S E L )

TRUCK, CARGO: 5-TON, 6X6

M813 (2320-00-050-8902) (EIC:BSB);

(2320-00-050-8890) (EIC:BSA)

M813A1 (2320-00-050-8913) (EIC:BSD);

[2320-00-050-8905) (EIC:BSC)

M814 {2320-00-050-8988) (EIC:BSK);

(2320-00-050-8987) (EIC:BSJ)

TRUCK, BOLSTER, LOGGING: 5-TON, 6X6

M815 (2320-00-050-8927) (EIC:BSE)

TRUCK, WRECKER, MEDIUM 5-TON, 6X6

M816 [2320-00-051-0489) (EIC:BSQ)

TRUCK, DUMP: 5-TON, 6X6

M817 (2320-00-050-8970) (EIC:BSF);

(2320-00-051-0589) (EIC:BSR)

TRUCK, TRACTOR 5-TON, 6X6

M818 (2320-00-050-8984) (EIC:BSH);

(2320-00-050-8978) (EIC:BSG)

TRUCK, TRACTOR, WRECKER 5-TON, 6X6

M819 (2320-00-050-9004) (EIC:BSL)

TRUCK, VAN, EXPANSIBLE: 5-TON, 6X6

M820 {2320-00-050-9006) (EIC:BSM)

M820A1 (2320-00-050-9007)

M820A2 (2320-00-050-9010) (EIC:BSN)

TRUCK, STAKE, BRIDGE TRANSPORTING: 5-TON, 6X6

M821 [2320-00-050-9015) [EIC:BSP).

D I S T R I B U T I O N S T A TE M E N T A. Ap pr ov ed f or p u bl ic r el ea s e ;

d i s t r i b u t i o n i s u n l i m i t e d .

D E P A R T M E N T S O F T H E A R M Y A N D T H E A I R F O R C E

A P R I L 1 9 9 5



TECHNICAL MANUALNO. 9-2320-260-20

TECHNICAL ORDERNo. 36A12-lC-491

Model

Truck, Cargo

Truck, Bolster, Logging

Truck, Wrecker, Medium

Truck, Dump

Truck, Tractor

Truck, Tractor, Wrecker

Truck, Van, Expansible

ARMY TM 9-2320-260-20AIR FORCE TO 36A12-lC-491

DEPARTMENTS OF THE ARMY AND THE AIR FORCE

WASHINGTON, D.C. 28 April 1995

TECHNICAL MANUAL

UNIT MAINTENANCE

5-TON, 6X6,

M813M813A1M814

M815

M816

M817

M818

M819

M820

M820A1M820A2

Truck, Stake, Bridge Transporting M821

FOR

M809 SERIES TRUCKS

(DIESEL)

NSN Without Winch (EIC)

2320-00-050-8902 (B S B )2320-00-050-8913 (B S D )2320-00-050-8988 (B S K )

2320-00-050-8970 (B S F)

2320-00-050-8984 (B S H )

NSN With Winch (EIC)

2320-00-050-8890 (B S A)2320-00-050-8905 (B S C )2320-00-050-8987 (B S J )

2320-00-050-8927 (B S E )

2320-00-051-0489 (B S Q)

2320-00-051-0589 (B S R)

2320-00-050-8978 (B S G )

2320-00-050-9004 (B S L )

2320-00-050-9006 (B S M)

2320-00-050-90072320-00-050-9010 (B S N)

2320-00-050-9015 (B S P )

This publi ca t ion su per sed es TM 9-2320-260-20-1, TM 9-2320-260-20-2-1, TM 9-2320-260-20-2-2,TM 9-2320-260-20-3-1, TM 9-2320-260-20-3-2, TM 9-2320-260-20-3-3, a nd TM 9-2320-260-20-3-4,da ted 12 J an ua ry 1981, for M809 Series Trucks.

DI STRIB U TION STATEM EN T A. Approved for public release;distr ibution is unlimited.

i



TM 9-2320-260-20

REPORTING OF ERRORS

You can help improve this ma nua l. If you f ind any mista kes or i f you know of a

wa y to improve the procedures, please let us know. Ma il your letter, D A Form 2028

(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 locatedin ba ck of th is ma nua l direct to: Command er, U.S . Army Tan k-Automotive Comman d,

ATTN: AMS TA-MB , War ren, Michiga n 48397-5000. A reply w ill be fu rn ished to y ou.

Page

IHOW TO U SE THI S MANU AL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

CHAPTER 1

Section I.

I I .

I I I .

CHAPTER 2

Section I.

I I .

I I I .

I V.

V.

VI .

VII.

CHAPTER 3

Section I.

I I .

I I I .

I V.

V.

VI .

VII .

CH AP TER 4

Section I.I I .

I I I .

I V.

V.

VI .

INTROD U CTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

P rinciples of Opera tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

SERVICE AND TROUBLESHOOTING INSTRUCTIONS . . . . . . . . . . . . . 2-1

Repair Parts, Special Tools, TMDE, and Support Equipment . . . . . . . . . . . . . . 2-1

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . 2-2

Mechanical Systems Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Compressed Air and Air-Hydraulic Brake System Troubleshooting . . . . . . . . . . 2-88

Electrical Systems Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

S TE /IC E Troublesh oot ing

(Simplified Test Equipment for Internal Combustion Engines) . . . . . . . . . . . . . 2-186

E NG INE SYS TE MS MAINTE NANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Engine Lubrication System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Clu tch Sys tem Main tenance .

Air Intake System Maintenance

Fuel Sys tem Main tenance . .

Accelera tor S ystem Maint enance

Exhaust System Maintenance .

Cooling System Maintenance . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

EL EC TRI CAL S YSTE M MAIN TE NANCE . . . . . . . . . . . . . . . . . . . . . . . 4-1

Charging System Maintenance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Starting System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Instruments, Sending Units, Switches, and Horn Maintenance . . . . . . . . . . . . . 4-13

Lighting System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Battery System Maintenance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

Wiring Circuits and Harness Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106

ii



TM 9-2320-260-20

CHAPTER 5

CHAPTER 6

CHAPTER 7

Section I.

I I .

I I I .

CHAPTER 8

Section I.

I I .

I I I .

CHAPTER 9

Section I.

I I .

CHAPTER 10

CHAPTER 11

Section I.

I I .

CHAPTER 12

Section I.

I I .

I I I .

I V.

V.

VI .

VII .

CHAPTER 13

Section I.

I I .

I I I .

TRANSMI SS ION MAINTE NANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSFE R CARE S YSTEM MAINTEN ANCE . . . . . . . . . . . . . . . . . . . . .

PROPELLER SHAFTS, AXLES, AND SUSPENSION

SYSTEM MAINTENANCE . . . . . . . . . . . . . . . .

P ropeller S ha fts Ma intena nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front and Rear Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front and Rear Suspension Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MECHANICAL PARKING BRAKE, COMPRESSED AIR,AND SERVICE BRAKE SYSTEM MAINTENANCE . . . . . . . . . . . . .

Mechanical Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Bra kes and H ydra ulic Syst em Maint enan ce . . . . . . . . . . . . . . . . . . . . .

Compressed Airan d B ra ke System Ma intena nce . . . . . . . . . . . . . . . . . . . . . . .

WHEELS, HUBS, DRUMS, AND STEERING SYSTEMMAINTENANCE . . . . . . . . . . . . . .

Wheels, Hubs, a nd D rums M a intena nce . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I BODY, CAB, AND ACCESSORIES MAINTENANCE . . . . . . . . . . . . . . . .

B odyan d C a b Ma intena nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessorie sIt emsMa int ena nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SP EC IAL P U RP OSE B ODIE S MAINTENANCE . . . . . . . . . . . . . . . . . . . .

Cargo Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dump Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van B ody Ma int ena nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wrecker Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor Wrecker Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolster Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractor Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOIST, WINCH, CRANE, AND POWER TAKEOFF MAINTENANCE

Hoist a nd Winch Maintena nce

Power Divider Maintenance

Power Takeoff Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

6-1

7-1

7-1

7-13

7-27

8-1

8-1

8-13

8-38

9-1

9-1

9-21

10-1

11-1

11-1

11-67

12-1

12-1

12-21

12-34

12-101

12-116

12-122

12-130

13-1

13-1

13-123

13-134

. .

ii



TM 9-2320-260-20

CHAPTER 14

Section I .

I I .

I I I .

I V.

V.

VI .

VII.

VIII .

I X.

X.

XI .

CHAPTER 15

Section I.I I .

I I I .

APP ENDIX A

APP ENDIX B

APP ENDIX C

APP ENDIX D

APP ENDIX E

INDEX

SP ECI AL P URP OSE KITS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .

Winterization Kits Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deepwater Fording Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-Frame Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mini Lighting Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100-Amp Alternator Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troop Seat and Seatbelt Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Airbrake Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachograph Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Convoy Warning Light Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Van Cable Reel Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-1

14-1

14-52

14-58

14-62

14-72

14-78

14-84

14-90

14-92

14-96

14-116

I SH IP ME NT AND L IMI TE D S TORAG E . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

General Preparation of Truck for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Loading and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Limited Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-1

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

EXP END AB LE/DU RAB LE SU P P LIE S AND MATERI ALS LIS T . . . . . . . . . . . C-1

TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. D-1

SCHEMATIC AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

i v



TM 9-2320-260-20

HOW TO USE THIS MANUAL

I ABOUT YOUR MANUAL

Spend some time looking thr ough this ma nua l . You’l l find t ha t i t ha s a new look, different th an most ofthe TM’s you’ve been using.

New features added to improve the convenience of this manual and increase your efficiency are:

a.

b.

c.

d.

e.

Accessing Information – These include features such as the bleed-to-edge locators on the cover andedge of the manual. Extensive troubleshooting guides for specific systems lead directly to step-by-stepdirections for problem solving an d ma intenan ce tasks.

Illustrations – A variety of methods are used to make locating and fixing components much easier.Locator i l lustrations with keyed text, exploded views, and cut-away diagrams make the informationin this manual easier to understand and fol low.

Modification or Special Purpose Kits – M809 series vehicles can be updated with modificationkits or equipped with special purpose kits. They allow the vehicle to operate more efficiently orperform a special function. Sometimes the vehicle being worked on doesn’t exactly match thema intenan ce procedure in this ma nua l because the proper kit ha s not been instal led. Refer to

troubleshooting sections in chapter 2 to find troubleshooting instructions or a reference to kitinstal lat ion instructions.

Keying Text With Illustrations – Il lustration and text are located on facing pages that show thespecific task you a re working on. In some cases, the t ask st eps and i l lustra tions are locat ed side byside. Continue reading for an example of modular t ext an d i l lustra tions.

General Features - Your TM is th e best source ava ilable for providing informat ion a nd da ta cri t icalto vehicle operation and maintenance:

S afe ty summary (wa rning pages a , b, C , and d)

General information, equipment description, and data (chapter 1, sections I and II)

Principles of operation (chapter 1, section III)

Preventive Maintenance Checks and Services – PMCS (chapter 2, section III)

Systems Troubleshooting (chapter 2, sections IV, V, VI, and VII)

Detailed maintenance procedures (chapters 3 through 14)

Shipment and l imited storage (chapter 15, sections I , II , and III)

References (appendix A)

Maintenance Allocation Chart – MAC (appendix B)

Expenda ble/dura ble supplies an d ma teria ls list (appendix C)

Torque limits (appendix D) Schematic and Wiring Diagrams (appendix E)

Atypical example of how to use this manual is provided on the following pages.

v



TM 9-2320-260-20

I USING YOUR MANUAL: AN EXAMPLE I

TASK: The operator of a M809 series vehicle,model number M813A1, has complained of exces-sive exhaust noise and exhaust fumes entering th ecab of his vehicle. The vehicle has been a ssigned t oyou for repair.

TROUBLESHOOTING STEPS:

1.

2.

3.

4.

5.

6.

7.

8.

9.

vi

Look a t t he cover of this ma nua l. You’ll seechapt er/section t itles list ed from t op to bott omon the right-hand side.

Look a t t he right-edge of the ma nua l. Onsome of th e pages y ou’ll see edge indicators

(black bars) that are alined with the chapter/section ba rs on t he cover. These a re th eloca tions of th e chapt ers/sections in th e text.

Look for “S ERVICE AND TROU B LES HOOT-ING INSTRU CTIONS” in t he chapter l ist onth e cover. This is w here t he tr oubleshootinginformation is located.

Turn to those pages with the edge indicatorma tching the black bar for service andtroubleshooting instructions. P age numbersa re a lso listed n ext t o cha pter/section t itles.

Chapter 2 is divided into seven sections:

Section I - Repa ir P a rt s, Special Tools,TMDE , and Support E quipment

Section II - Service Upon Receipt

Section III - Preventive MaintenanceChecks and Services (P MCS)

Section IV - Mechanical SystemsTroubleshooting

Section V - Compressed Air andAir-Hydr aulic Bra ke Syst emTroubleshooting

Section VI - Electrical SystemsTroubleshooting

Sect ion VII - STE/IC E Troublesh oot ing

Turn to section IV, “MEC HANIC ALSYSTEMS TROUBLESHOOTING”(pa ge 2-22). This tr oubleshootin g sect ionis system-oriented a nd is broken down into23 major vehicle syst ems.

One of the first pa ges of th is section is th e

“MECHANICAL TROUBLESHOOTINGSYMP TOM IN DE X” (tur n t o page 2-23).

Look down th e l ist unt il you f ind “EXHAUS TSYSTEM.” Beneath that heading you will f indthe symptoms noted by the vehicle operator:“Excessive exhaust noise” and “Exha ustfumes in cab.”

Turn to t he pa ge indicat ed: 2-30.



TM 9-2320-260-20

10.

11.

On page 2-30, step/test rela tin g t o resolvingthe problem of “Excessive exhaust noise” isl isted:

s tep 1 . Dur ing your inspect ion, you discovertha t an exhaust pipe is cracked a ndrusted. The part must be replaced.Cha pter 3, section VI is r eferenced.

Turn to the ‘TABLE OF CONTENTS” andfind the chapter dealing with the engine. Youfind i t as "CHAPTER 3, ENGINE SYSTEMSMAINTENANCE.” Furthermore, you notethat the chapter is divided into sevensections. You are interested in “Section VI.Exhaust System Maintenance.”

NOTE: Before attempting to repair or replace theexhaust system, as a Unit mechanic, you must:

12.

13.

14.

a. Determine the maintenance responsibilityof repair or replacement of the component.

b. If the task is at your echelon of mainte-nance responsibility, you must identifythe tools needed and the replacementparts required.

Refer to the Maintenance Allocation Chart- MAC (appendix B) to determine not onlythe maintenance responsibility of the item,but a lso to obta in an estimate of the t imerequired to perform the task, tools needed,a nd an y special notes/requirements n ecessary .

Refer t o TM 9-2320-260-20P, U ni t Mainte-nance Repair Parts and Special Tools List for

M809 Series Vehicles, for requisition dataconcerning replacement parts for this task.

Turn to chapter 3, section VI, which covers"EXHAUST SYSTEM MAINTENANCE.”In the maintenance index we find that thereare four para graphs l is ted.

P ara graph 3-41 is a t ask for replacing theexhaust system used only on model M821vehicles. All other M809 series vehicles willfollow para. 3-40 for replacement of theexha ust system. Notice tha t , in t his case,it starts on page 3-76.

The first two pages shown have proceduresand illustrations for performing the removalsteps for components of the exhaust system.

vii

http://027278.pdf/

http://027278.pdf/



TM 9-2320-260-20

DETAILED MAINTENANCE PROCEDURES:

15. Detailed procedures: Include everything you must do to accomplish a basic maintenance task.

a.B efore beginning th e ma intena nce task, look through t he procedure. You mu st familiarize yourself

with the ent ire ma intena nce procedure before beginning th e ma intenan ce task. The entire proce-

dure of paragraph 3-40: “VERTICAL EXHAUST PIPE MAINTENANCE” includes: a. Removal

and b. Ins ta l la t ion.

b. The eight basic headings listed under “INITIAL SETUP” outline special tools, materials, personnel

requirements, and special conditions. Headings will not be listed if there are no entries. The

headings are:

APPLICABLE MODELS Any models that r equire tha t part icular ma intenan ce ta sk.

TEST EQUIPMENT Test equipment needed to complete a task.

SPECIAL TOOLS Those special tools needed to complete a ta sk. Common t ools a re not list ed.

MATERIALS/PARTS All parts or mat erials needed t o complete a t ask.

PERSONNEL REQUIRED The num ber of personnel needed t o perform a ta sk. If only onemecha nic is needed, this hea ding will not be used. If you think tha t y ou need more help tocorrectly or safely complete a task (perhaps as the result of unusual conditions, etc.), alert

your supervisor and ask for help.

REFERENCES (TM) Those additional ma nua ls needed to complete a ta sk.

EQUIPMENT CONDITION Notes the conditions tha t must exist before sta rting t he ta sk. For

exhaust syst em repla cement, the vehicle must ha ve the parking bra ke set a nd th e air clean erelement removed.

GENERAL SAFETY INSTRUCTIONS Summa rizes a l l sa fety w arnings for t he maintenance task.

c.A step-by-step maintenance procedure follows the “INITIAL SETUP” and gives detailed instructions

16.

17.

18.

19.

20.

for the procedure. These instructions give part name and action performed. The numbers in paren-

theses correspond to the part’s callout number in the accompanying illustration. Warnings, cautions,

a nd notes give a dditional informa tion.

WARNINGS – Indicate conditions, practices, or procedures which must be observed to avoidpersonnel injury, loss of life, or long-term hea lth h a za rd.

CAUTIONS – In dicat e conditions, pra ctices, or procedures w hich must be observed to a voidda ma ge to equipment or destruction of equipment.

NOTES – Include essential information of special importance, interest, or aid in jobperformance .

d.At the end of a procedure, “FOLLOW-ON TASK S” w ill list t hose additional ta sks tha t m ust be

performed to complete t he procedure.

You ca n a lso use the Ta ble of Cont ents (page ii) to find more informa tion a bout t he vehicle. For

example: Principles of Operation in chapter 1.

U nit P MCS ar e presented in t able 2-1 star ting on page 2-4.

Ch a pter 2, section VII, STE/IC E Troubleshooting , can be used if S TE/IC E is a va ilable fortroubleshooting or P MCS.

Refer t o TM 9-2320-260-20P , U nit Ma intena nce Repair P a rt s a nd S pecial Tools List for Truck, 5-Ton,

6x6, M809 Series, when requisitioning parts, special tools, and equipment for unit maintenance.

Your ma nua l is easier to use once you underst a nd it s design. We hope it will encoura ge you to use itmore often as an aid to maintenance support for M809 series vehicles.

vi i i

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TM 9-2320-260-20

CHAPTER 1

INTRODUCTION

Section I. General Information (page 1-1)Section II. Equipment Description and Dat a (page 1-3)Section III. Principles of Operation (page 1-36)

Section I. GENERAL INFORMATION

1-1. SCOPE

a.This technical manual contains information for unit maintenance of 5-ton, 6x6, M809 series vehicles.

b.Vehicle model numbers and equipment names covered are:

M813 C a rg o Tru ck, W/W a nd WO/WM813A1 Ca rg o Tru ck, W/W an d WO/W (D ropsid e)M814 C a rg o Tru ck, W/W an d WO/W (XL WB)M815 B olst er L oggin g Tru ck, W/W

M816 Med ium Wrecker Tru ck, W/WM817 D um p Truck , W/W a nd WO/WM818 Tra ct or Tru ck, W/W a nd WO/WM819 Wrecker Tra ctor Tru ck, W/WM820 an d M820A1 E xpa ns ible Va n Tru ck, WO/WM820A2 Expa ns ible Va n Truck , WO/W (W/H LG )M821 Brid ge Tra nsport ing St a ke Truck, WO/W

c. The 5-ton, 6x6, M809 series trucks are designed for transporting and retrieving materials andpersonnel.

I 1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed

by DA Pam 738-750, The Army Maintenance Management System (TAMMS).

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army equipment to prevent enemy use can be found in TM 750-244-6.

1-4. PREPARATION FOR STORAGE OR SHIPMENT IStora ge and l imited storage instructions are in cha pter 15 of this ma nua l . Additional informa tion can

be found in TM 746-10, Marking, Packing and Shipment of Supplies and Equipment General PackagingInstructions for Field Use.

I 1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR’s)

If t he design of your vehicle needs improvement, let us know. I f your vehicle is in proper opera tingcondition and there are problems with vehicle or equipment performance, send us an EIR. You, the user, arethe only one who can tell us what you don’t like about your equipment. It is not necessary to show a new design or a better w ay to perform a procedure. J ust let us know wh y you don’t like the design orperformance. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at Commander, U.S. ArmyTank-Automotive and Armaments Command, ATTN: AMSTA-IM-MMAA Warren, Michigan 48397-5000.We’ll send you a reply .

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TM 9-2320-260-20

I 1-6. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)

The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains

valuable field information on the equipment covered in this manual. The information in the TB 43-0001-39

series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles

covered in th is ma nua l. Man y of th ese art icles resulted from comments, minor a lterat ions, proposedModifica tion Work Orders (MWO’s), a ctions ta ken on s ome of your D A form 2028’s (Recommended Ch a nges

to P ublicat ions), a nd a dvance informa tion on proposed changes t ha t ma y a ffect this ma nua l. The informa -tion will help you in doing your job better a nd w ill help in keeping you a dvised of the la test cha nges to

th is manual .

1-7. WARRANTY INFORMATION

The 5-ton, 6x6, M809 series Cum mins diesel engine (model NH C-250), a nd Da na tr a nsmission (model6453) a re w a rra nt ed in a ccorda nce wit h TB 9-2320-295-15/21. The w a rra nty sta rts on the d a te, found inblock 23, DA Form 2408-9, in the logbook. Report a ll defects in ma teria l or workma nship t o your supervisor,

wh o will ta ke appropriate a ct ion .

1- 2



TM 9-2320-260-20

Section II. EQUIPMENT DESCRIPTION AND DATA

1-8. GENERAL

The 5-ton, 6x6, M809 series trucks are tactical vehicles designed for use over all types of roads and cross-country terrain, in extreme high or low temperatures and humidity. All vehicles in this series are poweredby a 240 horsepower Cummins, NHC-250 series diesel engine. A five-speed manual transmission and two-speed transfer case provide ten overall speed ranges. The trucks are capable of fording hard-bottom watercrossings up to 30 inches (76.2 centimeters) without a deepwater fording kit, and 78 inches (198. 1 centi-meters) with the kit All trucks are also equipped with a rear pintle hook for towing operations. Two frontsha ckles an d a pin on top of the rea r springs provide a ready means of l i ft ing the tru ck for tra nsporta tion.

1-9. EQUIPMENT DESCRIPTION AND DATA INDEX

PARA.NO.

TITLE PAGE

NO.

1-10. Equipment Characteristics , Capabil i t ies , and Features 1-4

1-11. Location and Description of Major External Components 1-10

1-12. Location and Description of Major Internal Components 1-12

1-13. Locat ion a nd Contents of Warning , Caut ion, and Da ta P la tes 1-14

1-14. Differences Between Models 1-32

1-15. Vehicle Performance Data 1-33

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TM 9-2320-260-20

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

a. M813 Cargo Truck, W/W and WO/W.

P U RP OSE : This model is used to tr an sport cargo an d tr oops. The M813 has permanent steel-weldedsides, making it a preferred vehicle when t ra nsporting bulky or shif ting loads. S ide racks ha ve built-in tr oopseat s which ma y be positioned for tr oop tra nsport operat ions. A bow an d ta rpaulin kit is a vaila ble.

CARGO TRUCK (M813)

b. M813A1 Cargo Truck With Dropsides, W/W and WO/W.

P U RP OSE : This model is used to t ra nsport cargo an d t roops. The hinged steel sides can be foldeddown or removed for easy loading a nd unloading operations. Side ra cks ha ve built-in troop seat s wh ich ma y

be positioned for troop tra nsport operat ions. A bow an d t ar paulin kit is a vaila ble.

CARGO TRUCK, DROPSIDE (M813A1 )

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TM 9-2320-260-20

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)

c. M814 Cargo Truck With Extra Long Wheelbase (XLWB), W/W and WO/W.

PURPOSE: This model has the same load capacities as the M813 and M813A1. However, the M814truck bed is 72 in. (183 cm) longer. This provides each vehicle with an additional 744 cu ft (20.8 cu m) ofcargo space. ‘hop seata maybe positioned for troop transport operations.

d.

CARGO TRUCK (M814)

M815 Bolster Logging Truck, W/W.

PURPOSE: This model is used for transporting utility poles, bridge sections, and logs. It is equipped

with a cab protector, front an d midship winches, bolster assembly, an d a n a djusta ble M796 bolster t ra iler.

BOLSTER LOGGING TRUCK (M815)

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TM 9-2320-260-20


e. M816 Medium Wrecker Truck, W/W.

PURPOSE: This model is used for wrecker and salvage operations and has a revolving hydraulic

crane with a self-supporting boom that can extend from 10-18 ft (3.05-5.49 m). Boom-to-ground supportsare provided. Crane lifting capacity is 20,000 lb (9,080 kg). The vehicle is also equipped with a front winch

[20,000 lb (9,080 kg) capa city] a nd rea r w inch [45,000 lb (20,430 kg) capa city] for freeing th e vehicle wh enit becomes mired.

MEDIUM WRECKER TRUCK (M816)

f. M817 Dump Truck, W/W and WO/W.

PURPOSE: This model is used for hauling and dumping cargo. The body has provisions for installing

side rack, troop sea t, bow, a nd can vas kits for troop tra nsport. It can h au l up to 10,000 lb (4,540 kg) an d tow up to 15,000 lb (6,810 kg) when fully loaded. The front end of the welded steel body extends up and over the

vehicle cab t o protect it from da ma ge during loading opera tions.

DUMP TRUCK (M817)

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TM 9-2320-260-20

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (Contd)I

g. M818 Tractor Truck, W/W and WO/W.

P UR P OSE: This model is equipped w ith a f i fth wheel and is used to tra nsport semitrailers. The f i fthwh eel is ca pable of pivoting up to 21 degrees up, 15 degrees down, or 7 degrees sidewa ys. This ena bles theM818 to be more versatile in tactical operations under difficult conditions. Those equipped with a winch can

be used for recovery operat ions.

h.

TRACTOR TRUCK (M818)

M819 Wrecker Tractor Truck, W/W.

P UR P OSE: This model is used for w recker, hauling, and sa lvage opera tions. It ha s a hydra ulically-powered, engine-driven crane that is capable of extending 11.5-26 ft (3.5 1-7.93 m), rotating 270 degrees, andelevating 45 degrees. The M819 is also equipped with a fifth wheel for hauling semitrailers and a front

winch t o free the vehicle when it becomes mired.

WRECKER TRACTOR TRUCK (M819)

1-7



TM 9 2320 260 20


i. M820, M820A1, and M820A2 Expansible Van Truck, WO/W.

P URP OSE: These models are used for electrical, ma intenance,supply, power, a nd ba se stat ion

opera tions. The M820A2 ha s a hydr a ulic liftgat e [3,000 lb (1,362 kg) capa city], w hich ma kes it t he preferredvehicle to use when hea vy, delicate electronic equipment ha s to be moved in or out of the van .

EXPANSIBLE VAN TRUCK (M820)

EXPANSIBLE VAN TRUCK (M820A1)

1- 8



TM 9-2320-260-20


EXPANSIBLE VAN TRUCK, W/HLG (M820A2]

j. M821 Bridge Transporting Stake Truck, WO/W.

P URP OSE: This model is designed for t ran sport ing bridge building equipment a nd other cargo. I t isequipped with a front snatch Mock and rear roller for easier loading and unloading. The two hand-operatedwinches on the left side of the body and two winches at the rear of the body are used to secure a load on the

truck.

BRIDGE TRANSPORTING STAKE TRUCK (M821)

1- 9



TM 9-2320-260-20

1-11. LOCATION AND DESCRIPTION OF MAJOR EXTERNAL COMPONENTS

The externa l components described below a re common t o most of the vehicles covered in t his ma nua l.

Special differences can be found in TM 9-2320-260-10 or t a ble 1-1, Differences B etw een Models, in th ism a n u a l .

A ENGINE – Provides power for the vehicle.

B

C

D

E

F

G

H

I

J

K

L

M

N

1-10

LIFTING/TIEDOWN SHACKLES – U sed for lifting th e vehicle during sh ip-to-shore opera tions a ndfor t iedown a tt achments w hen tra nsporting vehicle.

FRONT WINCH – Powered by a propeller shaft extending from transmission power takeoff to permit

recovery operat ions.

TRANSMISSION – Manual transmission that transmits engine power to transfer case.

REAR PROPELLER SHAFT(S) – Transmits engine power from transmission to transfer case andthen t o rear dif ferentia ls.

FUEL TANK(S) – St ores fuel.

REAR BOGIE – Suspension system that supports rear vehicle weight.

TOWING PINTLE HOOK – Permits towing of vehicles, trailers, and other equipment.

REAR DIFFERENTIALS – Transmit power from propeller shafts through axles to wheels.

TRANSFER CASE – The two-speed transfer case, along with five forward speed transmission,provides 10 speed ranges to front and rear differentials.

AIR RESERVOIRS – Two st orage t a nks for compressed a ir.

FRONT PROPELLER SHAFT – Transmits engine power from transfer case to front differential.

FUEL FILTER AND WATER SEPARATOR – Filters contaminants from fuel.

AIR CLEANER – Filters a ir before i t enters the inta ke manifold.

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TM 9-2320-260-20

1-11. LOCATION AND DESCRIPTION OF MAJOR EXTERNAL COMPONENTS (Contd) I

1-11

cummins powered truck

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