TM 9-2350-238-34-2 Recovery Vehicle, Full-Tracked Light, Armored, m578
TM 9-2350-238-34-2 Recovery Vehicle, Full-Tracked Light, Armored, m578
TM 9-2350-238-34-2 Recovery Vehicle, Full-Tracked Light, Armored, m578
Supersedes copy
dated 4 October
1982. See page i
for details.
TECHNICAL MANUAL
DIRECT SUPPORT
DIRECT SUPPORT AND GENERAL TROUBLESHOOTING
PAGE 2-2
SUPPORT MAINTENANCE MANUAL
CHANGE HEADQUARTERS
No. 2 DEPARTMENT OF THE ARMY
Washington, DC 26 November 1993
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL
SUPPORT MAINTENANCE MANUAL
FOR
CRANE (CAB) COMPONENTS
RECOVERY VEHICLE, FULL-TRACKED:
LIGHT, ARMORED, M578
(2350-00-439-6242)
1. The purpose of this change notice is to provide notification under Section 326 of Public Law
102-484, FY 93 National Defense Authorization Act, that Ozone Depleting Chemicals may no
longer be used on Army equipment.
2. Throughout this publication the following items should be substituted for Ozone Depleting
Chemicals used on your equipment:
FOR: SUBSTITUTE:
Page B-3
MIL-P-23377 MIL-P-23377, Type 1.
3. File this change notice in the front of the publication for reference purposes.
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
05538
DISTRIBUTION:
*U.S.G.P.O.:1993-546-042:80083
TM 9-2350-238-34-2
C1
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 1 Washington, DC 28 May 1993
2. New or changed material is indicated by a vertical bar in the margin of the page.
3. Added or revised illustrations are indicated by a miniature pointing hand, or vertical bar adjacent
to the illustration identification number.
File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
04175
DISTRIBUTION:
WARNING
GENERAL
Dry cleaning solvent (SD2) is toxic and flammable. Wear protective goggles and gloves and use
only in well-ventilated areas.
Unusuable CARC mixtures may be considered hazardous waste and may require disposal IAW
Federal, state, DoD, and DA hazardous waste regulations. Consult the installation environmental
office for proper disposal guidance. Mixed CARC has a flashpoint of approximately 38°F (3°C)
due to the incorporation of solvents and is highly flammable.
CARC paint contains isocyanate, a constituent that can cause respiratory effects during and
after the application of the material. During the application of CARC paint, coughing, shortness
of breath, pain on respiration, increased sputum, and chest tightness may occur. CARC paint
also produces itching and reddening of the skin, a burning sensation of the throat and nose, and
watering of the eyes. An allergic reaction may occur after initial exposure (ranging from a few
days to a few months later), producing asthmatic symptoms including coughing, wheezing,
tightness in the chest, or shortness of breath. The following precautions must be observed to in-
sure the safety of personnel when CARC paint is applied.
• For brush/roller painting in confined spaces, an airline respirator is required, unless an air
sampling shows exposure to be below standards. If the air sampling is below standards,
either chemical cartridge or airline respirators are required.
• Spot painters applying CARC paint by brush or roller must wear clothing and gloves affor-
ding full coverage.
• Do not use water, alcohol, or amine based solvents to thin or remove CARC paints. Use of
these solvents with CARC paints can produce chemical reactions resulting in nausea,
disease, burns, or severe illness to personnel.
• Mix paint/coating in a well-ventilated mixing room or spraying area away from open flames.
Personnel mixing paint/coating should wear eye protection.
HYDRAULICS
Hydraulic system is under high pressure. Follow hydraulic system safety procedures to prevent
injury (TM 9-2350-238-20-2). Wipe up spilled hydraulic fluid.
Make sure hydraulic system is depressurized before performing any hydraulic maintenance to
prevent injury to personnel.
When testing hydraulic system, be sure boom is in stowed position as failure of system may
result in injury to personnel.
a
TM 9-2350-238-34-2
WARNING (CONT)
Make sure all personnel stand clear when operating boom to avoid injury to personnel.
Make sure all personnel stand clear of boom and block before traversing cab or operating boom.
Always wear leather gloves when handling winch cable. Never allow cable to run through hands.
Broken wires can cause painful injuries, Do not operate winch/crane with less than four turns of
wire rope on drums. Failure to observe these warnings could result in injury to personnel.
Vehicle drum winch assembly weighs approximately 400 lb (182 kg); use care when removing
or installing. Failure to observe this warning could result in injury to personnel and damage to
equipment.
Use hoist with lifting capacity of 2000 lb (908 kg) to prevent injury to personnel or damage to
equipment.
HYDRAULIC MOTOR
Hydraulic motor seal contains parts under spring tension. Use caution when removing or install-
ing hydraulic motor seal.
Clutch release carrier contains spring under high tension. Use caution during removal and
installation.
CAB
Make sure MASTER switch is OFF before repairing electrical components. Failure to observe this
warning could result in injury to personnel.
Use hoist and chain sling of 30,000 lb (13,620 kg) minimum lifting capacity to prevent injury to
personnel and damage to equipment.
RELIEF VALVE
Do not disconnect fittings or remove retainer caps until hydraulic pumps are shut off and system
pressure is relieved, Failure to follow instructions may result in injury to personnel or damage to
equipment.
FIRST AID
b
*TM 9-2350-238-34-2
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 the back of this manual, direct to: Commander, U.S.
Army Armament, Munitions and Chemical Command, ATTN: AMSMC-MAS,
Rock Island, IL 61299-6000. A reply will be furnished to you.
Table of Contents
Page
CHAPTER 1. INTRODUCTION
Section I, General information . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section II, Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
*This manual supersedes TM 9-2350-238-34-2, dated 4 October 1982, including all changes.
TM 9-2350-238-34-2
APPENDIX C. I L L U S T R A T E D L I S T O F M A N U F A C T U R E D I T E M S . . . . . . . . C-1
This manual (TM 9-2350-238-34-2) contains direct support and general support maintenance
procedures for the crane (cab) components of the M578 Recovery Vehicle, This manual is to be
used in conjunction with TM 9-2350 -238-20-2 and TM 9-2350-238-24P2. Chapter 1 contalns
general information and equipment description and data. Chapter 2 contains inforrnatior concer-
ning repair parts, special tools, TM DE, and support equipment; direct support troubleshooting;
and direct support maintenance procedures and information concerning preparation for storage
and shipment, Chapter 3 contains general support maintenance procedures and information con-
cering preparation for storage or shipment.
Be sure to read and understand maintenance instructions before beginning any maintenance
task. Also, read and understand information in Chapter 1 and general rnaintenance procedures
on page 2-16 before beginning any maintenance task,
ii
TM 9-2350-238-34-2
CHAPTER 1
INTRODUCTION
CHAPTER INDEX
Page
b. Model Number and Equipment Name. (1) Plans for destruction of equipment
M578 light armored, full-tracked recovery must be adequate, uniform, and easily carried
vehicle. out in the field.
1-1
TM 9-2350-238-34-2
a. Purpose. The M578 Recovery Vehicle is used to pick up or tow disabled mechanized
equipment, as a crane at repair base, and as a carrying platform for spare parts and maintenance
personnel.
1-2
TM 9-2350-238-34-2
Do not ford water which exceeds 42 in. (106.7 cm) in depth, Check for soft mud
or sandy bottoms.
(1) The M578 Recovery Vehicle is a light, full-tracked, self-propelled, diesel-powered vehi-
cle with a 30,000 lb (13,620 kg) boom winch and a 60,000 lb (27,240 kg) tow winch mounted
in an armored cab. It is highly mobile and maneuverable and may be air transported. The vehicle
is capable of long-range, high-speed operation on improved roads. It can travel over rough ter-
rain, muddy or marshy ground, snow or ice, and can ford streams of a depth of 42 in. (1 06.7
cm).
(2) A hydraulic suspension lockout system and a spade assembly provide a stable platform
and increase lifting and winching capabilities of the vehicle. Suspension lockout system, boom,
winches, cab, and spade are hydraulically powered.
(3) A machine gun mount support is installed on the rigger/gunner cupola to accommodate
a Browning M2.50 caliber machine gun.
(4) The cab can traverse 360 degrees using hydraulic power and travel up or down hills up
to 30 percent grade.
1-10. EQUIPMENT DATA. Necessary equipment data not furnished in this manual can be
found in TM 9-2350-238-10 or TM 9-2350-238-20-2.
a. B o o m W i n c h .
(1) Rated Load Capacity
Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,000 lb (6810 kg)
Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000 lb (13,620 kg)
( 2 ) a Hydraulic Motor to Drum Ratio
(a) Low . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . 73.09 to 1
(b) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 16.64 to 1
(3) Wire Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/8 in. (1.59cm)
(4) Wire Rope Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 ft (67m)
(5) Wire Rope Breaking Strength. . . . . . . . . . . . . . . . . . . . . . . 33.200 lb (15,073 kg)
(6) Wire Rope Spooling (line anchored) . . . . . . . . . . . . . . . . . Line puII 7500 lb (3405 kg)
(7) Drum Capacity
(a) Perfect Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 ft (109m)
(b) Uneven Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329 ft( 100m)
(8) Line Pull
(a) Low Speed, Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . . ..31,200 lb (14.165 kg)
(b) Low Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,100 lb (8671 kg)
(c) High Speed, Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7120 Ib (3232 kg)
(d) High Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4360 lb (1979 kg)
(9) Line Speed (approximate)
(a) Low Speed, Bare Drum..... . . . . . . . . . . . . . . . . . . . . . . . . 69 fpm (21 m/min)
(b) Low Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 fpm (34 m/min)
(c) High Speed, Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 fpm (93 m/min)
(d) High Speed, Full Drum..... . . . . . . . . . . . . . . . . . . . . . . . 496 fpm (151 m/min)
1-3
TM 9-2350 -238-34-2
b. Traversing System.
(1) Power Unit
(a) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 lb (56 kg)
(b) Dimensions. .17.25 x 16.50 x 14.50 in. (43.82 x 41.91 x 36.83 cm)
(c) Traversing range of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . .360 degrees
(2) Final Drive
(a) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 lb (35 kg)
(b) Dimensions . . . . . . . . . . . . . 16.00 x 11.75 x 7.50 in. (40.64 x 29.85 x 19.05 cm)
c. Tow Winch.
(1) Rated Load Capacity, Bare Drum. . . . . . . . . . . . . . . . 60,000 lb (27,240 kg)
(2) Hydraulic Motor to Drum Ratio
(a) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 to 1
(b) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...63 to 1
(3) Wire Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... l.0 in. (2.5 cm)
(4) Wire Rope Length . . . . . . . . . . . . ...........230 ft (70 meters)
(5) Wire Rope Breaking Strength . . . . . . . . . . . . . . . . . . . . . . . 84.000 lb (38,136 kg)
(6) Wire Rope Spooling (line anchored) . . . . . . . . . Line pull 30,000 lb (13,620 kg)
(7) Drum Capacity, Perfect Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 ft (99 meters)
(8) Line Pull
(a) Low Speed, Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . 71,500 lb (32,461 kg)
(b) Low Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 45,500 lb (20,657 kg)
(c) High Speed, Bare Drum..... . . . . . . . . . . . . . . . . . . . . . . . 17,650 lb (8013 kg)
(d) High Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,250 lb (5108 kg)
(9) Line Speed (approximate)
(a) Low Speed, Bare Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 28.7 fpm (8.7 m/min)
(b) Low Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 fpm (13.7 m/min)
(c) High Speed, Bare Drum . . . . . . . . . . . . . . . . . . 116.5 fpm (35.5 m/min)
(d) High Speed, Full Drum . . . . . . . . . . . . . . . . . . . . . . . . . .183 .5 fpm (55.9 m/min)
1-4
TM 9-2350 -238-34-2
CHAPTER 2
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
CHAPTER INDEX
Page
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Common Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16,
2-18
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Maintenance of Boom and Winch–Control Cylinders and Attaching Parts and
Boom Control Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2-84
Maintenance of Boom and Winch–Tow Winch Assembly . . . . . . . . . . . 2-103
Maintenance of Boom and Winch–Vehicle Drum Winch . . . . . 2-38
Maintenance of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-262
Maintenance of Cab Traversing Unit and Primary Planetary Speed Gear Assembly 2-227
Maintenance of Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-204
Maintenance of Check Valve 12253779-1 and Check Valve 12253779-2 2-177
Maintenance of Counterbalance Manifold Assembly . . . . . . . . . . . . 2-154
Maintenance of Hydraulic Flow Divider Manifold and Hydraulic Flow
Divider Plug Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-192
Maintenance of Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Maintenance of Planetary (Boom) Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Maintenance of Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-163,
2-205
Maintenance of Pressure Relief Valve 12253778-1 and Pressure Relief Valve
12253778-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179
Maintenance of Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-199
Maintenance of Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-208
Maintenance of Stage Four Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2-145
Maintenance of Stage One Boom Winch Carrier Assembly . . . . . . . . . . . . . . . . . . . . 2-69
Maintenance of Stage One Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Maintenance of Stage Three Boom Winch Carrier Assembly . . . . . . . . . . . . . . . 2-81
Maintenance of Stage Three Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
Maintenance of Stage Two Boom Winch Carrier Assembly . . . . . . . . . . . . . . . . . . 2-77
Maintenance of Stage Two Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
Maintenance of Three-Spool Directional Linear Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-151
Maintenance of Traversing Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-253
Maintenance of Traversing Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . 2-247
Maintenance of Traversing System Installation . . . . . . . . . . . . . . . . . . . . . 2-222
Maintenance of Turret Bearing Installation–Plain Bearing Unit and Outer
Race Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-269
Maintenance of Turret Traverse Control Directional Linear Valve and
Spool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217
Maintenance of Vehicle Tow Drum Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Maintenance of Winch Control Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Maintenance of Winch Level Wind and Connecting Link Slide . . . . . . . . . . . . . . . 2-21
Nonskid areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Painting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-1
TM 9-2350-238-34-2
2-1. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment,
refer to the Modified Table of Organization and Equipment (MTOE) applicable to your unit.
2-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Tools, special tools, and test
equipment necessary to maintain the M578 Recovery Vehicle are listed in TM 9-2350-238-24P-2
and appendix B of TM 9-2350-238-20-2. For an illustrated list of special tools and equipment,
refer to appendix E of this manual.
2-3. REPAIR PARTS. Repair parts are listed and illustrated in TM 9-2350-238-24P-2 covering
unit, direct support, general support, and depot maintenance for this equipment.
a. The symptom index can be used as a quick guide to troubleshooting. Common malfunc-
tions are listed in alphabetical order under each major assembly, which appear in MAC order,
with a page number reference to the troubleshooting table where a test or inspection and correc-
tive action are provided.
b. The direct support troubleshooting table lists the malfunction, the test or inspection in-
dicating the malfunction, and the necessary corrective action.
c. If the malfunction still exists after all listed direct support maintenance corrective actions
have been performed, notify general support maintenance.
d. This manual cannot list all malfunctions that may occur, nor all tests or inspections and
corrective actions. If a malfunction is not listed or is not corrected by listed corrective actions,
notify your supervisor.
2-2
TM 9-2350-238-34-2
Troubleshooting
Procedure
Page
CAB
TOW WINCH
BOOM WINCH
BOOM
LEVEL WIND
HYDRAULIC SYSTEM
2-3
TM 9-2350-238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CAB
Step 1. Check to make sure brake pressure selector knob is pushed in (normal
position) to allow system to operate.
2-4
TM 9-2350-238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 2. Check turret traverse control directional linear valve for damage.
Step 3. Check for damaged mini check valve in hydraulic flow divider manifold.
TOW WINCH
2-5
TM 9-2350-238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 5. Check adjustment of tow winch pressure relief valve. Refer to page
2-179.
Step 6 . Remove and disassemble vehicle tow drum winch. Refer to page 2-111.
Check for damaged parts.
2-6
TM 9-2350-238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2-7
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
BOOM WINCH
2-8
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 5. Check adjustment of boom winch pressure relief valve. Refer to page
2-179.
Step 6 . Remove and disassemble vehicle drum winch assembly. Refer to page
2-38.
10. BOOM WINCH PAYS IN, BUT WILL NOT PAY OUT.
11. BOOM WINCH PAYS OUT, BUT WILL NOT PAY IN.
Check adjustment of boom winch pressure relief valve. Refer to page 2-179.
2-9
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check adjustment of boom winch pressure relief valve. Refer to page 2-179.
BOOM
Step 2. Check boom winch control cylinders for damage and leaks.
2-10
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
If boom still will not raise, replace boom cylinder hydraulic stop-
check valve. Refer to page 2-154.
Step 1. Check for leaks and damaged or clogged hydraulic lines and hoses.
Step 2. Check boom winch control cylinders for damage and leaks.
Check adjustment of boom cylinder pressure relief valve. Refer to page 2-179.
2-11
TM 9-2350-238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
BOOM (CONT)
Step 1. Test boom for acceptable boom drop rates. Refer to page 2-84.
Step 4. Check for leaks around counterbalance manifold pressure relief valves.
Step 6. Check adjustment of boom cylinder pressure relief valve. Refer to page
2-179.
2-12
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
LEVEL WIND
2-13
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Check adjustment of hull return line solenoid valve. Refer to page 2-199.
HYDRAULIC SYSTEM
2-14
TM 9-2350 -238-34-2
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Fill hydraulic reservoir to full mark with lubricating oil (item 13,
appx B). Refer to TM 9-2350-238-10.
Refer to TM 9-2350-238-20-2.
2-15
TM 9-2350-238-34-2
2-5. GENERAL.
a. This section contains instructions on repair of hydraulic lines and fittings. Repair of hy-
draulic lines and fittings consists of replacement of preformed packings, tube fitting locknuts,
Iockwashers, and defective sleeve spacers and washers. Page 2-16 thru 2-17 show exploded
views of typical hydraulic lines and fittings used on the vehicle and give procedures for disas-
sembly and reassembly of fittings. For complete inspection procedures, refer to b. and c. below.
Refer to TM 9-2350-238-24P-2 for ordering of authorized parts. Ensure hydraulic pressure is
relieved before performing any disassembly of hydraulic lines and fittings.
b. Inspect all unions, nipples, tees, reducers, plugs, elbows, and parts, on which end fittings
are used, for thread damage, fractures, corrosion, distortion, slivers, restrictions, sealing surface
scratches, or mutilation. Hex corners shall not be rounded.
c. Inspect tube assemblies for kinks, fractures, cracks, thread damage, restrictions, corro-
sion, or mutilation. Tube ends shall be squared, deburred inside and out, and unprimed or un-
painted from sleeve flange to tube end. Tubes, 1/4 to 3/8 in. (6.35 to 9.53 mm) in diameter,
shall show no deformation of sleeves as a result of overapplication of torque. Repair is by
replacement of authorized parts (TM 9-2350-238-24P-2) which do not meet inspection criteria.
DISASSEMBLY
Remove tube fitting locknut (1), sleeve spacer
(2), tube elbow (3), tube fitting locknut (4),
flat washer (5), and preformed packing (6).
REASSEMBLY
DISASSEMBLY
Remove tube fitting locknut (1), flat washer
(2), and preformed packing (3). Disconnect
tube assemblies from tube tee (4) and remove
tube tee.
REASSEMBLY
2-16
TM 9-2350-238-34-2
DISASSEMBLY
REASSEMBLY
DISASSEMBLY
REASSEMBLY
DISASSEMBLY
Remove tube fitting locknut (1), sleeve spacer
(2), and straight adapter (3).
REASSEMBLY
2-17
TM 9-2350-238-34-2
1 Complete disassembly is not always neces- Dry cleaning solvent (SD2) is toxic
sary to make a repair. Exercise good judg- and flammable. Wear protective
ment to keep disassembly and assembly to goggles and gloves and use only in
a minimum. well ventilated areas.
2 Repair or replace unserviceable parts and 2 Clean metal parts with dry cleaning sol-
hardware. Always replace preformed pack- vent (item 5, appx B). Metal or fiber
ings, gaskets, seals, and cotter pins with brushes may be used to apply cleaning
new parts. solvent and to remove softened or dis-
solved material. Hand scraping with metal
3 Remove burrs with a stone or file. Remove scrapers may be used to remove soft
burrs on closely fitted mating surfaces by coatings or deposits.
lapping the surfaces with lapping grinding
compound (item 11, appx B). 3 Soak very oily or greasy metal parts in a
tank containing dry cleaning solvent (item
4 Remove corrosion or rust with sandblasting, 5, appx B). The time parts must be in sol-
vapor blast cleaning, or crocus cloth (item vent varies with the type and amount of
3, appx B). Use the method that will not material to be removed.
damage the surface being cleaned. Crocus
cloth should be used to remove corrosion 4 Do not use solvent to clean electrical in-
and rust from polished surfaces. Make sure sulation, wires, cables, or wiring har-
that critical dimensions are not changed nesses. Clean these parts by wiping with
when using crocus cloth. a damp cloth. Use a mild soap solution if
necessary. Dry immediately with clean,
5 Repair damaged threads with a thread chas- dry cloths. Clean contact points with flint
er, or by chasing in a lathe or die. abrasive paper (item 8, appx B) and dust
thoroughly after cleaning.
6 When welding is authorized, procedures in
TM 9-237 must be followed. Welds must 5 Do not use solvent to clean rubber parts.
be inspected for cracks. Clean rubber parts by washing with mild
solution of soap and water.
7 Bearings should be inspected and main-
tained per TM 9-214. 6 Dry parts by blowing with low-pressure
compressed air or wiping with clean lint-
2-13. TORQUE VALUES. Follow torque free cloths (item 4, appx B).
values given throughout this manual. When no
torque value is given, follow the torque limits 7 Bearings should be cleaned according to
guide, provided in appendix D of this manual, procedures in TM 9-214.
to prevent damaged parts. The guide is based
on using clean, dry threads.
2-18
TM 9-2350-238-34-2
8 Paint metal surfaces after repair as required. Sand and paint damaged areas. Apply one coat of
rust inhibitor primer (item 17, appx B). Allow primer to dry for 30 minutes minimum before ap-
plying enamel. Paint with enamel to match existing color; use white enamel (item 7, appx B) or
olive drab enamel (item 6, appx B).
2-15. LUBRICATION. Keep a light coat of lubricating oil (item 15, appx B) on parts during repair
procedures to prevent rusting. Lubricate parts during repair and assembly as required by TM 9-2350-238-
10 and TM 9-2350-238-20-2. I
2-16. PAINTING INSTRUCTIONS. Complete painting is authorized for and done by general sup-
port maintenance personnel or higher. Spot painting and restenciling vehicle markings is done by
unit maintenance personnel. Instructions for materiel preparation, priming, and finish are given in
TM 43-0139.
Nonslip paint (item 16, appx B) will be used to coat deck areas where personnel walk. The areas to
be coated with nonslip paint are shown shaded in the figures below.
Change 1 2-19
TM 9-2350-238-34-2
2-20
TM 9-2350-238-34-2
T h i s t a s k c o v e r s : a . Disassembly c. Reassembly
b. Inspection/Repair d. Adjustment
INITIAL SETUP
DISASSEMBLY
2-21
TM 9-2350-238 -34-2
DISASSEMBLY (CONT)
2-22
TM 9-2350-238-34-2
6 Remove three machine bolts (19), three 10 If damaged, remove two sleeve bearings
flat washers (20), and level wind access (30) from cross weldment bar (31).
cover (21).
11 Remove machine screw (32), Iockwasher
7 If damaged, remove four drive screws (33), chain assembly (34), and quick
(22) from each of three instruction plates release pin (28) from cross weldment bar
(23) and remove three instruction plates (31).
from level wind access cover (21).
12 Remove self-locking nut (35), and flat
8 Remove nut (24), Iockwasher (25), hex- washer (36) from shaft of cable guide
agon head capscrew (26), and hub slide (37).
clamp (27) from level wind housing (10).
13 Remove thrust washer bearing (38),
9 Disconnect quick release pin (28) and helical spring (39), sleeve spacer (40),
remove rigid connecting link (29) from and remote control lever (41) from shaft
level wind housing (10). of cable guide (37).
2-23
—
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
14 Using hammer and punch, remove spring 20 Remove two female terminal assemblies
Pin (42) from manual control lever (43). (55), two bushing sleeve insulators (56),
and two electrical shells (57) from each
15 Remove manual control lever (43), sleeve level wind sensing push switch (53).
spacer (44), and helical spring (45), from
shaft of cable guide (37). 21 Remove three nuts (58), three lock-
washers (59), three flat washers (60),
16 Using soft-faced hammer, remove cable three hexagon head capscrews (61), and
guide (37) and two thrust washer bear- level wind bracket (54) from level wind
ings (46). housing (10).
17 Using arbor press, remove two needle 22 Remove two sleeve bearings (62) from
roller bearings (47) from level wind hous- level wind housing (10).
ing (10).
23 Remove lubrication fitting (63) from level
18 Remove machine screw (48), Iockwasher wind housing (10).
(49), chain assembly (50), quick release
pin (51), and sleeve bushing (52) from 24 If damaged, remove three inserts (64)
cable guide (37). from level wind housing (10).
2-24
TM 9-2350-238 -34-2
INSPECTION/REPAIR
REASSEMBLY
2-25
TM 9-2350-238-34-2
REASSEMBLY (CONT)
11 Install remote control lever (26), sleeve 16 Install rigid connecting link (38) and
spacer (27), helical spring (28), and secure with quick release pin (32) to
thrust washer bearing (29) to shaft of level wind housing (2).
cable guide (19).
17 Install hub slide clamp (39), hexagon
12 Install flat washer (30) and new self- head capscrew (40), new Iockwasher
Iocking nut {31) to shaft of cable guide (41), and nut (42) to level wind housing
(19). (2).
13 Install quick release pin (32), chain 18 If removed, install three instruction
assemblv (33), new Iockwasher (34), dates (43) to level wind access cover
and machine screw (35) to cross weld- (44) with 12 new drive screws (45); four
ment bar (36). drive screws in each plate.
14 If removed, install two sleeve bearings 19 Install level wind access cover (44),
(37) to cross weldment bar (36). three flat washers (46), and three
machine bolts (47).
15 Apply a thin coat of grease (item 9, appx
B) to the bearing surfaces of the rigid
connecting link (38).
2-26
TM 9-2350-238-34-2
2-27
TM 9-2350-238-34-2
ADJUSTMENT
1 Remove three machine bolts (1), three flat 3 Back off self-locking nut (4) one-half turn.
washers (2), and level wind access cover
(3). 4 Tap underside of manual control lever (9)
to free lower sleeve spacer (8).
2 Tighten self-locking nut (4) until two
helical springs (5) are compressed and up-
per sleeve spacer (6) is tight against
2-28
TM 9-2350-238-34-2
5 Turn cable guide (10) until side of cable 9 Tighten three nuts (13) and unclamp
guide is perpendicular to axis of rigid cable guide (10).
connecting link (11) within 0.030 in.
(0.076 cm). 10 Position level wind sensing push swit-
ches (15) so they contact remote control
6 Clamp cable guide (10) to level wind lever (7), and then back off push swit-
housing (12) and hold in position. ches (15) one-half turn. Secure level
wind push switches (15) with mounting
7 Loosen three nuts (13) securing level nuts (16).
wind bracket (14) to level wind housing
(12). 11 Install level wind access cover (3) and
secure with three flat washers (2) and
8 Adjust level wind bracket (14) until three machine bolts (1).
remote control lever (7) is centered in
slot of level wind bracket (14). 12 After installation of level wind assembly
on vehicle, refer to TM 9-2350 -238-20-2
NOTE for final adjustment.
Level wind sensing push switches
(15) may be loosened if necessary,
2-29
TM 9-2350 -238-34-2
INITIAL SETUP
Materials/Parts
Spring tension washer (350-10025) Hydraulic motor seal contains
Winch motor parts kit (5702998) parts under spring tension. Use
caution when removing or install-
References ing hydraulic motor seal.
TM 9-2350-238-24P-2
DISASSEMBLY
2-30
TM 9-2350-238 -34-2
NOTE
Use care to ensure winch motor cam
ring and rotor do not separate.
2-31
TM 9-2350 -238-34-2
DISASSEAIBL Y (COIVT)
NOTE
Hydraulic motor seal is made up of
parts that are not repairable. If any
part(s) are damaged, repair is by re-
placement of entire hydraulic motor
seal.
2-32
TM 9-2350 -238-34-2
INSPECTION/REPAIR
2-33
TM 9-2350-238-34-2
REASSEMBLY
2-34
TM 9-2350-238-34-2
2-36
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-36 Change 1
TM 9-2350-238-34-2
NOTE
Ensure guide pin is installed in clock-
wise position.
2-37
TM 9-2350-238-34-2
INITIAL SETUP
Materials/Parts
Lockwasher (8) (MS35338-48) Use hoist with lifting capacity
Lockwasher (4) (MS35338-53) of 2000 lb (908 kg) to prevent
Lockwasher (4) (MS35338-67) injury to personnel and damage
Motor to winch gasket (1090871 O) to equipment.
2-38
TM 9-2350-238-34-2
REMOVAL
NOTE
Another M578 Recovery Vehicle or
M88A1 Recovery Vehicle may be
used, if available, for lifting.
2-39
TM 9-2350-238-34-2
REMOVAL (CONT) r
INSPECTION/REPAIR
INSTALLATION
2-40
TM 9-2350-238-34-2
NOTE
Another M578 Recovery Vehicle or
M88A1 Recovery Vehicle may be
used, if available, for lifting.
2-41
TM 9-2350-238-34-2
‘ T h i s t a s k c o v e r s : a . Disassembly c. Reassembly
b. Inspection/Repair d. Adjustment
INITIAL SETUP
Materials/Parts
Control cylinder gasket (10908418) Hydraulic system is under high
Cotter pin (MS24665-285) pressure. Follow hydraulic
Cylinder adapter plate gasket system safety procedures to pre-
(10908428) vent injury (TM 9-2350-238-
Hydraulic parts kit (5702990) 20-2). Wipe up spilled hydraulic
Lockwasher (4) (MS35338-46) fluid.
Preformed packing (MS28775-012)
Preformed packing (MS28775-212)
Sealing compound (item 18, appx B)
Winch brake parts kit (5702993)
References
TM 9-2350-238-20-2
TM 9-2350-238-24P-2
TM 9-4940-468-14
2-42 Change 1
TM 9-2350-238-34-2
DISASSEMBLE
2-43
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-44
TM 9-2350 -238-34-2
2-45
TM 9-2350-238-34-2
DISASSEMBLE (CONT)
2-46
TM 9-2350 -238-34-2
2-47
TM 9-2350-238 -34-2
DISASSEMBLEY (CONTI
2-48
TM 9-2350-238-34-2
2-49
TM 9-2350-238 -34-2
DISASSEMBLY (CONT)
2-50
TM 9-2350 -238-34-2
2-51
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-52
TM 9-2350-238-34-2
INSPECTION/REPAIR
1 Inspect for broken, damaged, or missing 5 Stage two boom winch carrier assembly is
parts. a repairable assembly. Refer to page 2-77.
2 If any kit component is damaged, replace 6 Stage three boom winch carrier assembly
entire repair parts kit. is a repairable assembly. Refer to page
2-81.
3 If cable reel is broken, damaged, or miss-
ing, repair is by replacement of next 7 Winch control cylinder is a repairable
higher assembly. assembly. Refer to page 2-64.
2-53
TM 9-2350-238-34-2
REASSEMBLY
2-54
TM 9-2350-238-34-2
2-55
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-56
TM 9-2350-238-34-2
2-57
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-58
TM 9-2350 -238-34-2
NOTE
Refer to TM 9-4940-468-14 for step
20 setup procedures.
2-59
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-60
TM 9-2350-238-34-2
2-61
TM 9-2350-238-34-2
REASSEMBLY (CONT)
RETAINING RING
PLIERS
2-62
TM 9-2350-238-34-2
ADJUSTMENT
2-63
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
NOTE
● There are two winch control
cylinders in the M578 vehicle.
Maintenance can be performed on
either winch control cylinder
without removing both cylinders.
2-64
TM 9-2350-238-34-2
2-65
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
INSPECTION/REPAIR
REASSEMBLY
2-66
TM 9-2350-238-34-2
2-67
TM 9-2350-238-34-2
REASSEMBLY (CONT)
test
2-68
TM 9-2350 -238-34-2
INITIAL SETUP
DISASSEMBLY
2-69
TM 9-2350-238-34-2
DISASSEMBLEY (CONT)
2-70
TM 9-2350-238-34-2
2-71
TM 9-2350 -238-34-2
DISASSEMBLY (CONT)
2-72
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
NOTE
If retaining stop ring and spur gear
were removed, new welds are
necessary during reassembly.
C A U T I O N
Weld retaining stop ring to carrier.
Do not weld to spur gear.
2-73
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-74
TM 9-2350-238-34-2
NOTE
● If a new carrier is used, drill and
tap a 0250-in. (0.635-cm), 28
UNF-2B hole, 0.375 in. (0.953
cm) deep between each gear
headless straight pin and carrier.
2-75
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-76
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-77
TM 9-2350-238-34-2
DISSASSEMBLY (CONT)
2-78
TM 9-2350-238-34-2
REASSEMBLY
NOTE
If retaining stop ring and spur gear
were removed, new welds are
necessary during reassembly.
2-79
TM 9-2350-238-34-2
REASSEMBLY (COIVT)
NOTE
. If a new carrier is used, drill and
tap a 0.250-in. (0.635-cm), 28
UNF-2B hole 0.375 in. (0.953 cm)
deep between each planet gear
pin and carrier.
2-80
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-81
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
INSPECTION/REPAIR
3 If any kit component is damaged, replace entire carrier assembly parts kit.
REASSEMBLY
2-82
TM 9-2350-238-34-2
2-83
TM 9-2350-238-34-2
INITIAL SETUP
2-84 Change 1
TM 9-2350-238-34-2
2-85
TM 9-2350238-34-2
REMOVAL (CONT)
2-86
TM 9-2350-238-34-2
NOTE
Steps 8 through 13 are written and
illustrated for removal of one boom
winch control cylinder assembly, but
apply to both.
NOTE
Number of spacers in step 9 may
vary depending on alinement of
boom winch control cylinder
assembly.
2-87
TM 9-2350-238-34-2
REI10VAL (CONT)
NOTE
Another M578 Recovery Vehicle or
M88A1 Recovery Vehicle may be
used, if available, for lifting.
NOTE
Disassembly procedures are written
and illustrated for one boom winch
control cylinder assembly but apply
to both.
2-88
TM 9-2350-238-34-2
2-89
TM 9-2350 -238-34-2
DISASSEMBLY (CONT)
2-90
TM 9-2350-238-34-2
INSPECTION/REPAIR
2-91
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-92 Change 1
TM 9-2350-238-34-2
SPANNER WRENCH
2-93
TM 9-2350-238-34-2
REASSEMBLY (CONT)
1 Refer to TM 9-4940-468-14 for test setup 4 Connect hydraulic line or hose (4) to port
and testing procedures. (3). Leave port (5), at closed end of boom
control cylinder assembly (2), open.
2 Retract hydraulic piston (1) into boom
control cylinder assembly (2). 5 Apply 4000 psi (27,580 kPa) hydraulic
pressure to boom control cylinder
3 Fill boom control cylinder assembly (2) assembly (2) through hydraulic line or
through upper port (3) with hydraulic fluid hose (4) for 5 minutes.
(item 10, appx B).
2-94
TM 9-2350-238-34-2
6 No leakage is allowed around open port (5), around hydraulic piston (1), or around boom
cylinder head (6).
7 If leakage occurs, disassemble boom control cylinder assembly (2) and check for damaged
parts.
8 If no leakage occurs, reduce pressure and remove hydraulic line or hose (4).
9 Drain hydraulic fluid (item 10, appx B) and plug cylinder ports (3) and (5).
INSTALLATION
NOTE
● Another M578 Recovery Vehi-
cle or M88A1 Recovery Vehicle
may be used, if available, for
lifting.
2-95
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-96
TM 9-2350-238-34-2
NOTE
Number of spacers in step 6 may
vary depending on alignment of
boom winch control cylinder
assembly.
2-97
TM 9-2350-238-34-2
● Make sure alll personnel stand clear when operating boom to avouid injury to per-
l sonnel.
Hydraulic syustem is under high pressure. Follow hydraulic system, safety pro-
c e d u r e s t o p r e v e n t i n j u y r y T M 9 - 2 3 5 0 - 2 3 8 - 2 0
2-98 Change 1
TM 9-2350-238-34-2
2-99
TM 9-2350-238-34-2
2-100
TM 9-2350-238-34-2
17 Using oil temperature recorded in step 2 and load drop rate figured in step 16, find boom
drop rate on chart A.
NOTE
The boom drop rate is within limits when it is below the maximum allowable
drop rate line in chart A.
19 Remove load from boom if boom drop rate is above the maximum allowable drop rate line in
chart A. Troubleshoot boom, refer to page 2-2.
2-101
TM 9-2350-238-34-2
21 Repeat steps 8 thru 19 for 15 ton (1 3.6 metric ton) load. (See chart C.)
2-102
TM 9-2350-238-34-2
INITIAL SETUP
Materials/Parts
Lockwasher (6) (MS35338-46)
Lockwasher (8) (MS35338-53)
Lockwasher (4) (MS35338-67) ● Hydraulic system is under high
Motor to winch gasket (1090871O) pressure. Follow hydraulic
system safety procedures to
Personnel Required prevent injury (TM 9-2350-
3 238-20-2). Wipe up spilled
hydraulic fluid.
References
TM 9-2350-238-20-2 ● Make sure hydraulic system is
TM 9-2350-238-24P-2 depressurized before performing
any hydraulic maintenance to
Equipment Conditions prevent injury to personnel.
Forward left-hand nonskid metallic tread
removed (TM 9-2350-238-20-2) ● Use hoist with minimum lifting
Elbow to winch control lines metal tube capacity of 2000 lb (908 kg) to
assemblies removed (TM 9-2350-238- prevent injury to personnel or
20-2) damage to equipment.
Boom and tow winch motor drain metal
2-103
TM 9-2350 -238-34-2
2-104 Change 1
TM 9-2350-238 -34-2
Change 1 2-105
TM 9-2350-238-34-2
REMOVAL (CONT)
WARNING
NOTE
Another M578 Recovery Vehicle or
M88A1 Recovery Vehicle, if
available, may be used for lifting.
2-106 Change 1
TM 9-2350-238-34-2
INSPECTION/REPAIR
INSTALLATION
WARNING
NOTE
Another M578 Recovery Vehicle or
M88A1 Recovery Vehicle, if avail-
able, may be used for lifting.
Change 1 2-107
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-108
TM 9-2350-238-34-2
2-109
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-110
TM 9-2350-238-34-2
T h i s t a s k c o v e r s : a . Disassembly c. Reassembly
b. Inspection/Repair d. Adjustment
INITIAL SETUP
2-111
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-112
TM 9-2350-238-34-2
2-113
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-114
TM 9-2350-238-34-2
2-115
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-116
TM 9-2350-238-34-2
2-117
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-118
TM 9-2350-238-34-2
2-119
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-120
TM 9-2350-238-34-2
INSPECTION/REPAIR
4 Stage one carrier assembly is a repairable 9 If any kit component is damaged replace
assembly. Refer to page 2-132. entire parts kit.
2-121
TM 9-2350-238-34-2
REASSEMBLY
2-122
TM 9-2350-238-34-2
2-123
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
Centerline of reaction end winch
support is drawn between mounting
lugs as illustrated.
2-124
TM 9-2350-238-34-2
MOUNTING LUGS
2-125
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-126
TM 9-2350-238-34-2
2-127
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
Refer to TM 9-4940-468-14 for step
23 setup procedures.
2-128
TM 9-2350-238-34-2
RETAING
RING PLIERS
29 Install self-aligning roller bearing (49)
and, using retaining ring pliers, install re-
taining ring (50) in motor end winch sup-
port (48).
2-129
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-130
TM 9-2350-238-34-2
drum (5).
NOTE
Refer to page 2-103 for tow winch
installation procedures.
ADJUSTMENT
Hydraulic system is under high 5 Tighten hexagon plain nut (3) until all
pressure. Follow hydraulic system slack is taken up.
safety procedures to prevent injury
(TM 9-2350-238-20-2). Wipe up 6 Tighten hexagon plain nut (3) an addi-
spilled hydraulic fluid. tional 1-1/2 turns, and secure hexagon
plain nut (3) in place with hexagon plain
1 Refer to TM 9-4940-468-14 for test setup nut (4).
and testing procedures.
7 Release hydraulic pressure and remove
2 Connect hydraulic line (1) to inlet port of hydraulic line from winch control cylinder
winch control cylinder (2). (2),
2-131
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-132
TM 9-2350-238-34-2
ARBOR
PRESS
2-133
TM 9-2350-238-34-2
DISASSEMBLY (CONT).
INSPECTION/REPAIR
REASSEMBLY
NOTE
If retaining stop ring and spur gear
were removed, new welds are
necessary during reassembly.
2-134
TM 9-2350-238-34-2
ARBOR
PRESS
2-135
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
2-136
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-137
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
ARBOR
PRESS
2-138
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
NOTE
If retaining stop ring and spur gear
shaft were removed, new welds are
necessary during reassembly.
ARBOR
PRESS
2-139
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
2-140
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-141
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
ARBOR
PRESS
2-142
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
NOTE
If retaining stop ring and spur gear
shaft were removed, new welds are
necessary during reassembly.
ARBOR
PRESS
2-143
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
● If a new carrier is used, drill and
tap a 0.250-in.(0.635-cm), 28
UNF-2B hole 0.375 in. (0.953
cm) deep between each gear
pin and carrier.
OLD HOLES
● If only new gear pins are used, NEW HOLES
drill and tap a new hole be-
tween each new gear pin and
carrier. Drill new holes approx-
imately 180 degrees from old
holes.
2-144
TM 9-2350-238-34-2
INITIAL SETUP
DISSSEMBLY
2-145
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-146
TM 9-2350-238-34-2
RETAINING
RING PLIERS ARBOR PRESS
2-147
TM 9-2350-238-34-2
INSPECTION/REPAIR
3 If any kit component is damaged, replace entire winch stage four carrier parts kit.
RESESSEMBLY
RETAINING
RING PLYIERS
ARBOR PRESS
2-148
TM 9-2350-238-34-2
2-149
TM 9-2350-238-34-2
REASSEMBLY (CONT)
NOTE
● If a new carrier is used, drill and
tap a 0.250-in.(0.635-cm), 28
UNF-2B hole 0.375 in.(0.953 cm)
deep between each gear pin and
carrier.
2-150
TM 9-2350-238-34-2
INITIAL SETUP
REMOVAL
Change 1 2-151
TM 9-2350-238-34-2
DISASSEMBLY
1 Remove six assembled screws (1) and 4 Remove three seal retainers (8) and three
three covers (2) from three-spool direc- preformed packings (9) from three-spool
tional linear valve housing (3). directional linear valve housing (3).
2 Remove six assembled screws (4) and 5 Remove three seal packing retainers (10),
three retainers (5) from three-spool direc- three valve spool wipers (11), and three
tional linear valve housing (3). preformed packings (12) from three-spool
directional linear valve housing (3).
3 Remove spool (6) and two spools (7) from
three-spool directional linear valve housing
(3).
2-152
TM 9-2350-238-34-2
6 Remove four plugs (13) and four pre- 2 Install three new preformed packings (19)
formed packings (14) from three-spool on three plugs (18).
directional linear valve housing (3).
Remove four preformed packings from 3 Install three plugs (18) in three-spool di-
four plugs. rectional linear valve housing (3).
7 Remove two plugs (15) with attached 4 install four new preformed packings (17)
parts from three-spool directional linear and four new retainers (16) on two plugs
valve housing (3). (15).
8 Remove four retainers (16) and four pre- 5 Install two plugs (15) in three-spool direc-
formed packings (17) from two plugs tional linear valve housing (3).
(15).
6 Install four new preformed packings (14)
9 Remove three plugs (18) and three pre- on four plugs (13).
formed packings (19) from three-spool
directional linear valve housing (3). Re- 7 Install four plugs (13) in three-spool direc-
move three preformed packings from three tional linear valve housing (3).
plugs.
8 Install three new preformed packings (12),
three new valve spool wipers (11), and
INSPECTION/REPAIR three new seal packing retainers (10) in
three-spool directional linear valve housing
(3).
1 Inspect for broken, damaged, or missing
parts.
9 Install three new preformed packings (9)
and three seal retainers (8) in three-spool
2 If three-spool directional linear valve hous-
directional linear valve housing (3).
ing is broken, damaged, or missing, repair
is by replacement of next higher assem-
10 Install two spools (7) and spool (6) in
bly.
three-spool directional linear valve housing
(3).
3 If any kit component is damaged, replace
entire three-spool valve parts kit.
11 Install three new retainers (5) and six new
assembled screws (4) on three-spool di-
4 Repair is by replacement of authorized
rectional linear valve housing (3).
parts (TM9-2350-238-24P-2).
2-153
TM 9-2350-238-34-2
INSTALLATION
INITIAL SETUP
Tools and Special Tools References
General mechanic’s tool kit, automotive TM9-2350-238-20-2
(SC5180-90-CL-N26) TM9-2350-238-24P-2
2-154 Change 1
TM 9-2350-238-34-2
REMOVAL/DISASSEMBLY
2 Remove two manifold tee tube cam (4), 3 Remove manifold tee tube cap {14), check
two fitting to tee metal tube assemblies valve to tee metal tube assembly (15),
(5), two check valve to tee metal tube metal fitting tube assembly (16), valve
assemblies (6), two valve tube tees (7), tube tee (17), check valve to tube pipe
two flow control fluid restrictors (8), two elbow (18), flow control fluid restrictor
preformed packings (9), and two check (19), and preformed packing (20) from
valve to tube pipe elbows (10) from pres- pressure relief valve (21) and multiple cen-
sure relief valve (11), pressure relief valve nector (13).
(12), and multiple connector (13).
2-155
TM 9-2350-238-34-2
REMOVAL/DISASSEMBLY (CONT)
2-156
TM 9-2350-238-34-2
2-157
TM 9-2350-238-34-2
REMOVAL/DISASSEMBLY (CONT)
INSPECTION/REPAIR
2-158
TM 9-2350-238-34-2
3 Check valves (1253779-1 and 12253779-2) are repairable assemblies. Refer to page
2-177.
4 Pressure relief valves (12253778-1 and 12253778-2) are repairable assemblies. Refer to
page 2-179.
REASSEMBLY/INSTALLATION
NOTE
● Apply engine oil (item 15, appx B)
to all preformed packings before
installation.
2-159
TM 9-2350-238-34-2
REASSEMBLY/INSTALLATION (CONT)
2-160
TM 9-2350-238-34-2
2-161
TM 9-2350-238-34-2
REASSEMBLY/lNSTALLATION (CONT)
23 Install new preformed packing (40) on 27 Install counterbalance manifold (54), four
flow control fluid restrictor (41) new Iockwashers (55), and four counter-
balance manifold machine bolts (56).
24 Install flow control fluid restrictor (41),
check valve to tube pipe elbow (42), 28 Refer to page 2-163 for adjustment of
valve tube tee (43), metal fitting tube pressure relief valves.
assembly (44), check valve to tee metal
tube assembly (45), and manifold tee 29 Refer to page 2-177 for adjustment of
tube cap (46). check valve.
25 Install two new preformed packings (47) 30 Refer to page 2-179 for adjustment of
on two flow control fluid restrictors (48). boom cylinder pressure relief valve.
26 Install two flow control fluid restrictors 31 Refer to page 2-179 for adjustment of
(48), two check valve to tube pipe el- tow winch pressure relief valve.
bows (49), two valve tube tees (50),
two check valve to tee metal tube as- 32 Refer to page 2-179 for adjustment of
semblies (51), two fitting to tee metal boom winch pressure relief valve.
tube assemblies (52), and two manifold
tube caps (53).
2-162
TM 9-2350-238-34-2
INITIAL SETUP
2-163
TM 9-2350-238-34-2
DISASSEMBLY
2-164
TM 9-2350-238-34-2
INSPECTION/REPAIR
1 Check for broken, damaged, or missing 11 If pilot cap is broken, damaged, or miss-
parts. ing, repair is by replacement of next
higher assembly.
2 If check spring plug is broken, damaged,
or missing, repair is by replacement of 12 If adjusting screw is broken, damaged, or
next higher assembly. missing, repair is by replacement of next
higher assembly.
3 If valve spring is broken, damaged, or
missing, repair is by replacement of next 13 If hexagon plain nut is broken, damaged,
higher assembly. or missing, repair is by replacement of
next higher assembly.
4 If check valve is broken, damaged, or
missing, repair is by replacement of next 14 If adjusting screw retainer is broken,
higher assembly. damaged, or missing, repair is by re-
placement of next higher assembly.
5 If socket capscrews are broken, dam-
aged, or missing, repair is by replace- 15 If spring seat is broken, damaged, or
ment of next higher assembly. missing, repair is by replacement of next
higher assembly.
6 If cover cap is broken, damaged, or
missing, repair is by replacement of next 16 If poppet spring is broken, damaged, or
higher assembly. missing, repair is by replacement of next
higher assembly.
7 If filter disc is broken, darnaged, or miss-
ing, repair is by replacement of next 17 If poppet is broken, damaged, or miss-
higher assembly. ing, repair is by replacement of next
higher assembly.
8 If filter disc adapter is broken, damaged,
or missing, repair is by replacement of 18 Repair is by replacement of authorized
next higher assembly. parts (TM 9-2350-238-24P-2).
2-165
TM 9-2350-238-34-2
REASSEMBLY
2 Install pilot cap (3) and four socket cap- 7 Install adjusting screw (19), and hexagon
screws (4) on pressure relief valve body plain nut (20) in pilot cap (3).
(5).
8 Install check valve (21), valve spring (22),
3 Install spool spring (6), spool (7), filter new preformed packing (23), and check
disc adapter (8), and filter disc (9) in pres- suring plug (24).
sure relief valve body (5).
9 Perform installation procedures prior to ad-
4 Install new preformed packing (10) and justment of pressure relief valves. Refer to
new preformed packing (11) in cover cap page 2-154.
(12).
2-166
TM 9-2350-238-34-2
ADJUSTMENT
● Make sure all personnel stand clear when operating boom to avoid injury to personnel.
● When testing hydraulic system, be sure boom is in stowed position as failure of system
may result in injury to personnel.
NOTE
Steps 1 thru 5 are written for one
pressure relief valve, but apply to all
three.
OIL PRESSURE
TESTER
2-167
TM 9-2350-238-34-2
ADJUSTMENT (CONT)
Hydraulic system is under high pressure. Follow hydraulic system safety pro-
cedures to prevent injury (TM 9-2350-38-20-2). Wipe UP spilled hydraulic fluid.
NOTE
Steps 6 thru 19 are written for right
pressure relief valve.
2-168
TM 9-2350-238-34-2
2-169
TM 9-2350-238-34-2
ADJUSTMENT (CONT)
2-170
TM 9-2350-238-34-2
NOTE
Steps 20 thru 33 are written for left
pressure relief valve.
2-171
TM 9-2350-238-34-2
ADJUSTMENT (CONT)
2-172
TM 9-2350-238-34-2
29 Lower load to ground and allow boom 32 Slowly push BOOM WINCH control han-
winch cable to slacken. dle (13) to LOWER to remove air trapped
in pressure relief valve (15).
30 Turn off hydraulic system. Refer to TM
9-2350-238-10. 33 Install manifold tee tube cap (1) on valve
tube tee (2).
31 Disconnect oil pressure tester from valve
tube tee (2).
2-173
TM 9-2350-238-34-2
ADJUSTMENT (CONT)
Hydraulic system is under high pressure. Follow hydraulic system safety pro-
cedures to prevent injury (TM 9-2350-238-20-2). Wipe up spilled hydraulic fluid.
NOTE
Steps 34 thru 52 are written for middle pressure relief valve.
2-174
TM 9-2350-238-34-2
2-175
TM 9-2350-238-34-2
2-176
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
NOTE
● Disassembly procedures are writ-
ten for one pressure relief valve,
but apply to both.
2-177
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
NOTE
● Reassembly procedures are writ-
ten for one pressure relief valve,
but apply to both.
ADJUSTMENT
2-178
TM 9-2350-238-34-2
INITIAL SETUP
2-179
TM 9-2350-238-34-2
DISASSEMBLY
2-180
TM 9-2350-238-34-2
2 Remove preformed packing (4) from pilot 10 If spring seat is broken, damaged, or
cap (2). missing, repair is by replacement of next
higher assembly.
3 Remove preformed packing (5), piston
guide (6), piston spring (7), and piston 11 If poppet is broken, damaged, or miss-
(8) from pressure relief valve body (3), ing, repair is by replacement of next
higher assembly.
4 Remove hexagon plain nut (9), adjusting
screw (10), and using retaining ring 12 If poppet spring is broken, damaged, or
pliers, remove retainer (11). missing, repair is by replacement of next
higher assembly.
5 Remove spring seat (12), preformed
packing (13), poppet spring (14), and 13 Repair is by replacement of authorized
poppet (15) from pilot cap (2). parts (TM 9-2350-238-24P-2).
INSPECTION/REPAIR REASSEMBLY
2-181
TM 9-2350-238-34-2
● Make sure all personnel stand clear when operating boom to avoid injury to personnel.
NOTE
● Perform installation procedures prior
to adjustment of pressure relief
valves. Refer to page 2-154.
2-182
TM 9-2350-238-34-2
NOTE
Turn screw clockwise to increase
pressure and counterclockwise to
decrease pressure.
2-183
TM 9-2350-238-34-2
2-184
TM 9-2350-238-34-2
OIL PRESSURE
TESTER
2-185
TM 9-2350-238-34-2
3 Remove spring cap (1) from tow winch pressure relief valve (2).
4 Install 3000 psi (20,685 kPa) oil pressure tester in test port (3).
2-186
TM 9-2350-238-34-2
OIL PRESSURE
TESTER
Hydraulic system is under high pressure. Follow system safety procedures to prevent
injury (TM 9-2350-238-20-2). Wipe UP spilled hydraulic fluid.
D O not allow pressure to go over 2000 psi (13,790 kpa). Failure to follow instructions
may result in damage to equipment.
10 Hold TOW WINCH control handle (8) in full IN position and read oil Pressure tester”
11 Adjust pressure for tow winch pressure relief valve (2) to between 1625 and 1775 psi
(11,204 and 12,229 kPa) by turning screw (9) counterclockwise to decrease pressure or
clockwise to increase pressure.
2-187
TM 9-2350-238-34-2
2-188
TM 9-2350-238-34-2
OIL PRESSURE
TESTER
1 Perform adjustment of check valve pro- 4 Install 3000 psi (20,685 kpa) oil pres-
cedures. sure tester in test port (3).
2 Turn off hydraulic system. Refer to 5 Set boom winch shift control lever (4) to
TM 9-2350-238-10. HI.
3 Remove spring cap (1) from boom winch 6 Pull out BOOM WINCH BRAKE PRES-
pressure relief valve (2). SURE SELECTOR knob (5).
2-189
TM 9-2350-238-34-2
2-190
TM 9-2350-238-34-2
OIL PRESSURE
TESTER
2-191
TM 9-2350-238-34-2
INITIAL SETUP
References
TM 9-2350-238-20-2
TM 9-2350-238-24P-2
2-192 Change 1
TM 9-2350-238-34-2
REMOVAL/DISASSEMBLY
2-193
TM 9-2350-238-34-2
REMOVAL/DISASSEMBLY (CONT)
2-194
TM 9-2350-238-34-2
NOTE
Step 13 is written for disassembly of hydraulic flow divider plug valve.
13 Remove valve assembly machine thread plug (38), compression cup (39), shouldered wash-
er (40), and preformed packing (41) from flow divider valve (42).
INSPECTION/REPAIR
6 If flow divider valve is broken, damaged, or missing, repair is by replacement of next higher
assembly.
2-195
TM 9-2350-238-34-2
REASSEMBLY/INSTALLATION
NOTE
● Apply engine oil (item 15, appx B)
to all preformed packings before
installation.
2-196
TM 9-2350-238-34-2
2-197
TM 9-2350-238-34-2
REASSEMBLY/INSTALLATION(CONT)
2-198
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
NOTE
These procedures are written and il-
lustrated for relief valve (PN
12253774). If your unit has a
damaged relief valve (PN
10922171), order relief valve (PN
12253774), in accordance with TM
9-2350-238-24P-2.
2-199
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
1 Apply engine oil (item 15, appx B) to 3 Install pressure adjust screw (7) in re-
new preformed packing (1). tainer cap (5).
2 Install poppet (2), poppet spring (3), new 4 Install hexagon plain nut (8) on pressure
preformed packing (1), spring seat (4), adjust screw (7).
and using retaining ring pliers, install re-
tainer cap (5) in relief valve (6).
2-200
TM 9-2350-238-34-2
ADJUSTMENT
NOTE
Perform installation procedures prior
to adjustment of pressure relief
valve. Refer to page 2-192.
2-201
TM 9-2350-238-34-2
ADJUSTMENT (CONT)
2-202
TM 9-2350-238-34-2
OIL PRESSURE
TESTER
2-203
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
NOTE
These procedures are written and il-
lustrated for check valve (PN
12253775). If your unit has a dam-
aged check valve (PN 10922174),
order check valve (PN 12253775) in
accordance with TM 9-2350-238-
24P-2.
2-204
TM 9-2350-238-34-2
INSPECTION/REPAIR
REASSEMBLY
INITIAL SETUP
2-205
TM 9-2350-238-34-2
2-206
TM 9-2350-238-34-2
4 If piston guide is broken, damaged, or 1 Apply engine oil (item 15, appx B) to
missing, repair is by replacement of next new preformed packings (13, 5, and 4)
higher assembly. and piston (8).
5 If pilot cap is broken, damaged, or miss- 2 Install poppet (15), poppet spring (14),
ing, repair is by replacement of next new preformed packing (13), spring seat
higher assembly. (12), and using retaining ring pliers, in-
stall retainer cap (11).
6 If pilot capscrews are broken, damaged,
or missing, repair is by replacement of 3 Install pressure adjusting screw (10), and
next higher assembly. hexagon plain nut (9) in pilot Cap (2).
7 If pressure adjusting screw is broken, 4 Install piston (8), piston spring (7), piston
damaged, or missing, repair is by guide (6), and new preformed packing
replacement of next higher assembly. (5) in valve body (3).
8 If hexagon plain nut is broken, damaged, 5 Install new preformed packing (4) on
or missing, repair is by replacement of pilot cap (2).
next higher assembly.
6 Install pilot cap (2) and four pilot
9 If retainer cap is broken, damaged, or capscrews (1) on valve body (3).
missing, repair is by replacement of next
higher assembly.
ADJUSTMENT
10 If spring seat is broken, damaged, or
missing, repair is by replacement of next Refer to page 2-179 for adjustment of
higher assembly. pressure relief valve.
2-207
TM 9-2350-238-34-2
INITIAL SETUP
DISASSEMBLY
2-208
TM 9-2350-238-34-2
2 Remove preformed packing (4) from pilot 8 If adjusting screw hexagon plain jam nut
cap (2). is broken, damaged, or missing, repair is
by replacement of next higher assembly.
3 Remove preformed packing (5), piston
guide (6), piston spring (7), and piston 9 If retainer cap is broken, damaged, or
(8) from valve body (3). missing, repair is by replacement of next
higher assembly.
4 Remove adjusting screw hexagon jam
nut (9), pressure adjusting screw (10), 10 If spring seat is broken, damaged, or
and using retaining ring pliers, remove re- missing, repair is by replacement of next
tainer cap (11). higher assembly.
6 Remove solenoid valve (16) from pilot 12 If poppet is broken, damaged, or miss-
cap (2). ing, repair is by replacement of next
higher assembly.
7 Remove preformed packing (17), packing
retainer (18), and preformed packing (19) 13 If solenoid valve is broken, damaged, or
from solenoid valve (16). missing, repair is by replacement of next
higher assembly.
2-209
TM 9-2350-238-34-2
REASSEMBLY
1 Apply engine oil (item 15, appx B) to 5 Install pressure adjusting screw (15), and
new preformed packings (1, 2, 3, 4, and adjusting screw hexagon jam nut (16) in
5), piston guide (6), piston (7), and pack- pilot cap (10).
ing retainer (8).
6 Install piston (7), piston spring (17), pis-
2 Install new preformed packing (1), pack- ton guide (6), and new preformed Pack-
ing retainer (8), and new preformed ing (4) in valve body (18).
packing (2) on solenoid valve (9).
7 Install new preformed packing (5) on pi-
3 Install solenoid valve (9) on pilot cap lot cap (10).
(lo).
8 Install pilot cap (10) and four pilot cap-
4 Install poppet (11), poppet spring (12), screws (19) on valve body (18).
new preformed packing (3), spring seat
(13), and using retaining ring pliers, in- 9 Perform installation procedures prior to
stall retainer cap (14). high-pressure setting adjustment of sole-
noid valve. Refer to page 2-192.
2-210
TM 9-2350-238-34-2
● Make sure all personnel stand clear when operating boom to avoid injury to
personnel.
2-211
TM 9-2350-238-34-2
2-212
TM 9-2350-238-34-2
NOTE
As level wind sensing switch ac-
tuates, the solenoid valve should
click.
2-213
TM 9-2350-238-34-2
2-214
TM 9-2350-238-34-2
OIL
PRESSURE
TESTER
2-215
TM 9-2350-238-34-2
OIL
PRESSURE
5 Set LEVEL WIND switch (4) to OFF. TESTER
OIL
PRESSURE
TESTER
2-216
TM 9-2350 -238-34-2
INITIAL SETUP
Change 1 2-217
TM 9-2350-238-34-2
REMOVAL
DISASSEMBLY
Wipe up spilled hydraulic fluid to 4 Remove retaining ring (7), spacer (8),
prevent injury to personnel. helical spring (9), washer (10), and
spacer (11) from spool (12),
1 Remove check valve (1) from body (2). 7 Remove preformed packing (16) from
plug valve (15).
2 Remove preformed packing (3) and
backup ring (4) from check valve (1).
2-218
TM 9-2350 -238-34-2
INSPECTION/REPAIR
-—
1 Check for broken, damaged, or missing 7 If port fitting is broken, damaged, or
parts. missing, repair is by replacement of next
higher assembly.
2 If assembly plug is broken, damaged, or
missing, repair is by replacement of next 8 If turret traverse control valve body
higher assembly. nameplate is broken, damaged, or miss-
ing, repair is by replacement of next
3 If body is broken, damaged, or missing, higher assembly.
repair is by replacement of next higher
assembly. 9 If drive screws are broken, damaged, or
missing, repair is by replacement of next
4 If plug valve is broken, damaged, or higher assembly.
missing, repair is by replacement of next
higher assembly. 10 If spool seal retainer is broken, damaged,
or missing, repair is by replacement of
5 If check valve is broken, damaged, or next higher assembly.
missing, repair is by replacement of next
higher assembly. 11 If spacers are broken, damaged, or miss-
ing, repair is by replacement of next
6 If spool cap is broken, damaged, or miss- higher assembly.
ing, repair is by replacement of next
higher assembly.
2-219
TM 9-2350-238-34-2
INSPECTION/REPAIR (CONT)
REASSEMBLY
NOTE
Apply engine oil (item 15, appx B)
to all new preformed packings and
spools.
2-220
TM 9-2350-238-34-2
7 Install new preformed packing (19) on 11 Install spool assembly (29) and spool cap
plug valve (20). (30) in body (7).
8 Install plug valve (20) in body (7). 12 Install new backup ring (31) and new
preformed packing (32) on check valve
9 Install new preformed packing (21) and (33).
new packing retainer (22) in body (7).
13 Install check valve (33) in body (7).
10 Install spacer (23), washer (24), helical
spring (25), spacer (26), and retaining
ring (27) on spool (28).
INSTALLATION
2-221
TM 9-2350-238-34-2
INITIAL SETUP
REMOVAL
2-222 Change 1
TM 9-2350-238-34-2
NOTE
Another M578 Recovery Vehicle
or M88A1 Recovery Vehicle may SLING
be used, if available, for lifting.
2-223
TM 9-2350-238-34-2
REMOVAL (CONT)
INSPECTION/REPAIR
INSTALLATION
2-224
TM 9-2350-238-34-2
2-225
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-226
TM 9-2350-238-34-2
INITIAL SETUP
Materials/Parts
Cotter pin (MS24665-357)
Engine oil (item 15, appx B)
Key washer (MS19070-072)
Lockwire (QQW461)
Retaining ring (7) (MS16624-1075)
Retaining ring (MS16624-1087)
Sealing compound (item 20, appx B)
Traversing system power unit kit
(5705024)
Change 1 2-227
TM 9-2350-238-34-2
DISASSEMBLY
2-228
TM 9-2350-238-34-2
SCRIBED
L I N E
2-229
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
DRIFT
2-230
TM 9-2350238-34-2
DRIFT
2-231
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
ARBOR
PRESS
17 Using fabricated pipe with cutout (fig. 2,
appx C) and arbor press, compress slip PIPE WITH
CUTOUT
clutch spring (39) and remove machine
key (40) from shouldered brake shaft
(38).
2-232
TM 9-2350-238-34-2
2-233
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
SPANNER
WRENCH
2-234
TM 9-2350-238-34-2
RETAINING
RING PLIERS
NOTE
Steps 27 thru 31 are written for
disassembly of primary planetary
speed gear assembly.
2-235
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
ARBOR
PRESS
2-236
TM 9-2350-238-34-2
INSPECTION/REPAIR
5 If any kit component is damaged, replace entire traversing system power unit kit.
REASSEMBLY
2-237
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-238
TM 9-2350-238-34-2
2-239
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-240
TM 9-2350-238-34-2
2-241
TM 9-2350-238-34-2
REASSEMBLY(CONT)
2-242
TM 9-2350-238-34-2
2-243
TM 9-2350-238-34-2
REASSEMBLY(CONT)
2-244
TM 9-2350-238-34-2
2-245
TM 9-2350-238-34-2
REASSEMBLY(CONT)
2-246
TM 9-2350-238-34-2
INITIAL SETUP
2-247
TM 9-2350-238-34-2
DISASSEMBLY
2-248
TM 9-2350-238-34-2
2-249
TM 9-2350-238-34-2
DISASSEMBLY(CONT)
INSPECTION/REPAIR
2-250
TM 9-2350-238-34-2
2-251
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-252
TM 9-2350-238-34-2
NOTE
Perform step 19 only if motor is be-
ing prepared for storage or ship-
ment. Motor is filled with oil and
plug is installed to retain oil during
storage or shipment.
INITIAL SETUP
2-253
TM 9-2350-238-34-2
DISASSEMBLY
2-254
TM 9-2350-238-34-2
2-255
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
NOTE
Steps 10 thru 15 are written and il-
lustrated for one idler spur gear, but
apply to both.
2-256
TM 9-2350-238-34-2
15 Remove retaining
spur gear (10).
INSPECTION/REPAIR
2-257
TM 9-2350-238-34-2
REASSEMBLY
NOTE
Steps 1 thru 8 are written and il-
lustrated for one idler spur gear, but
apply to both.
2-258
TM 9-2350-238-34-2
NOTE
If key washer is damaged, new key
washer must be installed.
2-259
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-260
TM 9-2350-238-34-2
2-261
TM 9-2350-238-34-2
INITIAL SETUP
References
TM 9-2350-238-24P-2
SERVICE
REMOVAL
2-262 Change 1
TM 9-2350-238-34-2
8 Disconnect hull return line nonmetallic hose assembly (20) from tube tee (19) on pump and
slip ring assembly (6). Cover hose assembly opening.
9 Remove hex nut (21), Iockwasher (22), and screw (23) and disconnect bearing rod end (24)
from cab wall.
10 Remove hex nut (25), Iockwasher (26), and screw (27) and disconnect bearing rod end (24)
from welded bracket on pump and slip ring assembly (6).
2-263
TM 9-2350-238-34-2
REMOVAL (CONT)
NOTE
To remove 28 screws and Iockwashers in step
11, turret must be traversed to make
approximately four screws and Iockwashers
accessible at a time.
NOTE
Ensure center of gravity is obtained
when positioning sling and hoist.
Approximate center of gravity can
be obtained by alining the hoist with
the center of left side cab swinging
metal door and right side cab vehicle
hatch door.
2-264 Change 1
TM 9-2350-238-34-2
NOTE
● When cab assembly is removed or installed in a maintenance shop, position vehicle in
an area with minimum ceiling clearance of 20 ft (6 m).
● Removal of the cab assembly can be performed using a second M578 Recovery Vehicle
or an M88A1 Recovery Vehicle. Both vehicles must be positioned on a hard surface
with spade down to remove or install the cab assembly.
15 Lift cab assembly (33) straight up and free of hull. Place cab on wood blocks.
INSPECTION/REPAIR
2 If plain bearing unit or outer race assembly are broken or damaged, refer to page 2-269.
INSTALLATION
NOTE
● Prior to installing cab assembly,
refer to page 2-269 for servic-
ing the plain bearing unit and
outer race assembly.
2 Using a sling and hoist of 30,000 lb (13,620 kg) minimum lifting capacity, connect sling to
crowbar and lifting eyes (1) on top of cab assembly (2).
2-265
TM 9-2350-238-34-2
INSTALLATION (CONT)
NOTE
● Remove three alinement pins
from turret bearing when install-
ing screws and Iockwashers in
step 7.
2-266
TM 9-2350-238-34-2
8 Connect bearing rod end (10) to welded bracket on pump and slip ring assembly (11) and
secure with screw (12), new Iockwasher (13) and hex nut (14).
9 Connect bearing rod end (10) to cab wall and secure with screw (15), new Iockwasher
(16), and hexagon nut (17).
10 Uncover hull return line nonmetallic hose assembly (18) opening and reconnect to tube tee
(19) on pump and slip ring assembly (11).
11 Uncover metal tube assembly (20) opening and reconnect to tube tee (19) on pump and slip
ring assembly (11).
12 Uncover openings of two nonmetallic hose assemblies (21 and 22). Install two new
preformed packings (23) and two nonmetallic hose assemblies (21 and 22) to Pump and
slip ring assembly (11). Secure with four split flange clamp halves (24), eight new
Iockwashers (25), and eight hexagon head capscrews (26).
2-267
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-268
TM 9-2350-238-34-2
INITIAL SETUP
Change 1 2-269
TM 9-2350-238-34-2
REMOVAL
NOTE
Check the position of the plain bear-
ing unit before removing it from the
cab assembly, The plain bearing unit
should be rotated 180 degrees from
the original position after scheduled
maintenance has been performed to
prevent uneven wear.
2-270 Change 1
TM 9-2350-238-34-2
DISASSEMBLY
2-271
TM 9-2350-238-34-2
DISASSEMBLY(CONT)
8 Using hoist and sling, raise outer race (4) slightly to remove weight from ball bearings (7).
NOTE
It may be necessary to rotate outer race two or more complete turns to locate and
remove all ball bearings and retainers.
9 Using magnetic retrieving tool for ball bearings (7) and tweezers for retainers (8), remove
100 to 103 ball bearings and 100 to 103 retainers through turret filler plug opening (9).
2-272
TM 9-2350-238-34-2
2-273
TM 9-2350-238-34-2
DISASSEMBLY (CONT)
2-274
TM 9-2350-238-34-2
INSPECTION/REPAIR
Dry cleaning solvent (SD2) is toxic and flammable. Wear protective goggles and
gloves and use only in well-ventilated area.
2 Remove adhesive from upper and lower surfaces of outer race (1) with wire brush and dry
cleaning solvent (item 5, appx B).
3 Remove sealing compound from seal retaining plates (2) and hexagon head capscrews (3)
with wire brush and dry cleaning solvent (item 5, appx B).
4 Clean retainers (4) with soft brush and mild soap solution.
5 If turret filler plug is broken, damaged, or missing, repair is by replacement of next higher
assembly.
6 Outer race is unserviceable if there are five or more pits within a 12.00 in. (30.48 cm)
distance, or any pit is more than 1.00 in. (2.54 cm) long, 0.06 in. (0.16 cm) wide, or 0.03
in. (0.08 cm) deep.
7 If inner race is broken, damaged, or missing, repair is by replacement of next higher assembly.
9 Repair is by replacement of authorized parts (TM 9-2350-238-24P-2) which do not meet in-
spection criteria.
2-275
TM 9-2350-238-34-2
REASSEMBLY
NOTE
Make sure grease (item 9, appx B) is
not applied to seal surfaces of outer
race.
BOLT
2-276
TM 9-2350-238-34-2
3 Install three eye lifting bolts in threaded holes of inner race (2) an equal distance apart.
5 Lift and center inner race (2) over outer race (1).
6 Carefully lower inner race (2) into outer race (1) and aline ball bearing grooves.
NOTE
Alinement is correct when ball bearings can be installed without difficulty.
7 Support weight of inner race (2) with hoist so it can be turned easily during installation of
ball bearings (3) and retainers (4).
NOTE
Prior to installation, lubricate ball bearings using grease (item 9, appx B).
8 Install ball bearing (3) through filler plug hole (5) in outer race (1) and push ball bearing (3)
to one side in groove.
9 Install retainers (4) through filler plug hole (5) in outer race (1) and fit ball bearings (3) in
groove.
10 Turn inner race (2) and continue installing one ball bearing (3) and one retainer (4) until tur-
ret bearing (6) is filled with 100 to 103 ball bearings and 100 to 103 retainers. The last
item installed must be a ball bearing fitted between two retainers.
11 Lower inner race (2) and remove sling and three eye lifting bolts.
2-277
TM 9-2350-238-34-2
REASSEMBLY (CONT)
2-278
TM 9-2350-238-34-2
2-279
—
TM 9-2350 -238-34-2
REASSEMBLY (CONT)
2-280
TM 9-2350-238-34-2
INSTALLATION
NOTE
When cab assembly is lifted within a
maintenance shop, position vehicle
in an area with minimum ceiling
clearance of 20 ft (6 m).
2-281
TM 9-2350-238-34-2
INSTALLATION (CONT)
2-282 Change 1
TM 9-2350-238-34-2
CHAPTER 3
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
APPENDIX A
REFERENCES
A-1. SCOPE. This appendix lists all forms, field manuals, technical manuals, and
miscellaneous publications referenced in this manual.
A-2. FORMS.
A-1
TM 9-2350-238-34-2
A-2 Change 1
TM 9-2350-238-34-2
APPENDIX B
Section 1. INTRODUCTION
B-1. SCOPE. This appendix lists expendable/durable supplies and materials you will need to
operate and maintain the M578 Armored, Light, Full-Tracked Recovery Vehicle. This listing is for
informational purposes only and is not authority to requisition the listed items. These items are
authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, Repair
Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items.
a. Co/umn (1)–Itern Number. This number is assigned to the entry in the listing and is
referenced in the narrative instructions to identify the material (e.g., adhesive (item 1, appx B).
b. Co/umn (2)–Level. This column identifies the lowest level of maintenance that requires
the listed item,
c. Column (3)–National Stock Number, This is the national stock number assigned to the
item; use it to request or requisition the item.
d. Column (4)-Description. Indicates the Federal item name and, if required, a description to
identify the item, The last line for each item indicates the Contractor and Government Entity
Code (CAGEC) in parentheses followed by the part number.
e. Column (5)–Unit of Measure (U/M). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by a two-character alphabetical abbreviation
(e.g., ea, in., pr). If the unit of measure differs from the unit of issue, requisition the lowest unit
of issue that will satisfy your requirements.
1 F ADHESIVE
MM-A-189
8040-00-204-5841 402 can OZ
8040-00-264-5840 1 gal. container GL
8040-00-543-7170 1 pint can PT
B-1
TM 9-2350-238-34-2
B-2
TM 9-2350-238-34-2
12 Deleted I
13 F 9150-00-231-2350 LUBRICATING OIL GL
(8.349)MIL-L-3150
APPENDIX C
C-1. INTRODUCTION. This appendix includes complete instructions for making items author-
ized to be manufactured or fabricated at direct support and general support maintenance.
a. A part number index in alphanumeric order is provided for cross-referencing the part
number of the item to be manufactured to the figure which covers fabrication criteria.
b. All bulk materials needed for manufacture of an item are listed by part number or specifi-
cation number in a tabular list on the illustration.
Part Figure
Number Number
595552 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Non applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
c-1
TM 9-2350-238-34-2
Fabricate pipe with cutout from: Use steel pipe with a wall at least 3/1 6-in. (0.48 cm)
thick. Inside diameter can be from 2-3/4 to 3-1/8-in.
(6.99 to 7..94 cm).
C-2
TM 9-2350-238-34-2
APPENDIX D
TORQUE VALUES
D - 1 . Follow torque values given throughout this manual. When no torque value is given, follow
the guide to prevent damaging parts.
D-1
TM 9-2350-238-34-2
D-2
TM 9-2350-238-34-2
APPENDIX E
E-1. GENERAL. Repair parts, special tools, and support equipment are issued for maintaining
the vehicle. Tools and equipment should not be used for purposes other than those prescribed.
When not in use, they should be properly stowed.
E-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. Special tools and equipment
necessary to perform the maintenance described in this manual are listed for your information.
Special tools and support equipment are listed in TM 9-2350-238-24P-2 which is the authority
for requisitioning replacements.
E-3. REPAIR PARTS. Repair parts are issued for the replacement of parts that have become
worn, broken, or otherwise unserviceable. Repair parts are listed in TM 9-2350-238-24P-2
which is the authority for requisitioning replacements,
E1
TM 9-2350-238-34-2
HANDLE, REPLACER
E-2
TM 9-2350-238-34-2
REPLACER
REPLACER, BEARING
E-3
TM 9-2350-238-34-2
REPLACER, BEARING
SCREW, JACKING
E-4
TM 9-2350-238-34-2
SCREW, JACKING
SCREW, JACKING
SEAL INSERTER
SLING
E-5
TM 9-2350-238-34-2
E-6
TM 9-2350-238-34-2
WRENCH, SPANNER
WRENCH, SPANNER
WRENCH, STRAP
ALPHABETICAL INDEX
Index-1
TM 9-2350-238-34-2
Index-2 Change 1
TM 9-2350-238-34-2
index-3
TM 9-2350-238-34-2
Index-5
TM 9-2350-238-34-2
T (cont) W
Index-6
TM 9-2350-238-34-2
FIGURE FO-1
FIGURE FO-1
FIGURE FO-2