TorcUP TU-2 - Page 30

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ASSEMBLY
GENERAL INSTRUCTIONS
1. Use extra care not to score, nick, or damage surfaces that will contain hydraulic oil under
pressure.
2. Whenever grasping a tool in a vise, always use leather–covered or copper–covered vise jaws to
protect the surface of the part and help prevent distortion. This is particularly true of threaded
members and housings.
3. ApplyO–ringlubricanttoallO–ringsbeforenalassembly.
Inspect all parts prior to assembly. Replace any worn or
damaged parts.
MAINTENANCE SECTION
ASSEMBLY OF THE TU-2, TU-3, TU-7, AND TU-11 CYLINDER ASSEMBLIES
1. Install the cylinder ring (35) into the groove at the inlet end of the housing.
2. Clamp the housing (1) in copper–covered or leather–covered vise jaws with the inlet end facing
downward.
3. Insert the end plug (19), small end leading, into the bore of the housing. Using a brass drift, tap the
end plug into the cylinder approximately 1/2”.
4. Insert the piston rod assembly (20), shaft trailing, into the bore of the housing. Using a brass drift,
tap the piston rod assembly into the housing until the end plug bottoms out against the cylinder ring
(35).
5. Thread the cylinder gland (23) into the housing. Tighten with the gland wrench (50) and a socket
untilushwiththehousing.
6. Reposition the housing in the vice with the inlet end upward.
7. Wraptheswivel(39)threadswithTeontape.Installtheswivelwiththemalecouplerintotheport
marked ‘A’ (on the right when looking at the inlets) and the swivel with the female coupler into the
port marked ‘R’ (on the left when looking at the inlets).
8. Connect the tool to a pump and cycle several times to check for leaks.
9. If leaks are present, disconnect the hoses and take the necessary steps to correct the problem.
If no leaks are detected, disconnect the hoses and re-clamp the tool in the vise with the inlet end
downward.
10. Stake the thread of the gland and housing. Make certain the stake point deforms both the housing
and gland.
11. Wipeathinlmofmarinemolygreaseonthesidesofthedriveplate(13)aswellastheinnerrace
and piston rod recess of the drive plate.
12. Insert the ratchet (11) into the drive plate (13).
13. Position the drive segment (12) at the cavity ensuring the ratchet and drive segment engage
properly. If they will not engage properly, reverse the ratchet in the drive plate.
14. Insert the segment springs (26) into the holes of the drive segment and compress the springs while
installing the drive segment into the drive plate.
15. Wipeathinlmofmarinemolygreasearoundtheoutsideofthedrivesleeves(18)andinstall,with
the shoulder trailing, into the bores on each side of the housing.
16. Insert the drive plate assembly into the housing with the notch for the piston rod toward the piston,
ensuring alignment of the holes in the drive plate and piston.
17. Insert the roll pin (22) into the hole in the drive plate through the hole in the housing. Use a drift and
hammer to tap the pin into the plate making certain the pin does not protrude beyond either side of
the drive plate.
NOTICE