TM-9-2320-260-20
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; UNIT MAINTENANCE
APRIL 1995
TM-9-2320-260-20 - Page 7 of 1337
TM 9-2320-260-20
REPORTING OF ERRORS
You can help improve this manual. If you find any mistakes or if you know of a
way to improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located
in back of this manual direct to: Commander, U.S. Army Tank-Automotive Command,
ATTN: AMSTA-MB, Warren, Michigan 48397-5000. A reply will be furnished to you.
Page
I
HOW TO USE THIS MANUAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
CHAPTER 1
Section I.
II.
III.
CHAPTER 2
Section I.
II.
III.
IV.
V.
VI.
VII.
CHAPTER 3
Section I.
II.
III.
IV.
V.
VI.
VII.
CHAPTER 4
Section I.
II.
III.
IV.
V.
VI.
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
STE/ICE Troubleshooting
(Simplified Test Equipment for Internal Combustion Engines) . . . . . . . . . . . . . 2-186
ENGINE SYSTEMS MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Lubrication System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Clutch System Maintenance .
Air Intake System Maintenance
Fuel System Maintenance . .
Accelerator System Maintenance
Exhaust System Maintenance .
Cooling System Maintenance . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-74
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-84
ELECTRICAL SYSTEM MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 4-1
Charging System Maintenance.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Starting 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
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