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TRAC-TROL CABLE ASSEMBLY
AND SEAL REPLACEMENT INSTRUCTIONS:
1. Remove the unit from machinery,
and place on clean work table.
2. Loosen the set screws (#24) in the
trolley (#25), and then disconnect the
old cable subassemblies (#8) from the
trolley.
3. Remove the retaining rings (#21),
and then remove the two guide rods (#23)
and the trolley (#25).
4. Remove the four headbolts (#2) at
each end, and separate the heads (#3)
from the ends of the tube (#14).
5. Grasp the cable and pull to bring
the piston (#13) out of the tube at one
end.
6. Cut both cables off the piston,
and discard the old cables.
7. Before proceeding to remove the
piston screws (#35) from the piston
(#13), it may be necessary to slightly
heat the piston to break down the
threadlocker that secures the cables to
the piston. Start by wrapping the piston
with cloth (exposing only the piston
nose which requires heating) and place
in a round jaw vice; be careful not to
damage the piston.
8. Gradually heat up the piston (#13)
with a propane torch as you unscrew each
of the cut cable ends from the piston.
9. Allow piston (#13) to cool before
removing from vice.
10. Lubricate all seals with
pneumatic grease (Magnalube-G® with
Teflon®, or similar) for pneumatic
service, or oil treatment (STP® Oil
Treatment, or similar) for hydraulic or
low-friction service.
11. Replace the piston u-cups (#10)
with new (observe the orientation of the
old u-cups)
12. Replace all of the seals in the
heads: The head o-rings (#6), the
cushion seals (#7), and the needle
o-rings (#5).
13. Clean the tube (#14).
14. Determine which end of the new
cable assembly (#8) should connect to
the piston (#13): The piston end should
have the shorter piston-screw (#35), and
the trolley end should have the longer
trolley-screw (#31). Take care not to
scratch the nylon on the cable.
15. Replace the cable seal (#34) into
the head (#3) by tucking in the lips,
and replace the pilot washer (#33)
between the head and the rod flange
(#22).
16. Apply threadlocker (Loctite® 242
or similar) to the piston screw (#35),
and tighten it all the way into the
piston (#13).
17. Lubricate a few inches inside the
tube (#14) in front of the piston (#13),
and then push the piston back into the
tube by gently tucking in the lips of
the piston u-cup (#10).
18. Attach the head (#3), rod flange
(#22), and sheave bracket (#17) to the
tube (#14) with the four screws (#2).
19. Move the piston (#13) to the
opposite end of the tube (#14) by
applying a controlled air supply to the
port. Make sure the air flow rate is set
very low to prevent high speeds.
20. Repeat steps 14 - 19 for the
other cable at the other end of the
tube.
21. Replace trolley (#25), guide rods
(#23), and retaining rings (#21).
22. Connect the trolley screws (#31)
to the trolley (#25).
23. Proof-load and pretension the
cable according to the Proof-loading
instructions.
24. After the cables are properly
tensioned, retighten the two set screws
(#24) that are in the trolley (#25).
March 2009
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