TorcUP TU-2 - Page 31

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MAINTENANCE SECTION
18. Use a hex wrench to loosen the square drive locking pin (15) enough so that the square drive pin
isushwiththesquaredrive.
19. Insert the square drive into the housing through the drive sleeves (18) and tighten the drive
locking pin so that the square drive can slide freely without sliding out.
20. Place one end of the shroud (24) on the housing and, using a hex wrench, thread the shroud
screws (25) part way in.
21. Bend the shroud around the housing and install the remaining screws, going back and tightening
the screws from the previous step.
Inspect all parts prior to assembly. Replace any worn or
damaged parts.
ASSEMBLY OF THE TU-5, TU-20, TU-27, AND TU-60 CYLINDER ASSEMBLIES
Note: TU-20 part numbers are bold.
1. Install the cylinder ring (35) (34) into the groove at the inlet end of the housing.
2. Clamp the housing (1) (1) in copper–covered or leather–covered vise jaws with the inlet end
downward.
3. Insert the end plug (19) (20), 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) (21), 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.
5. Thread the cylinder gland (23) (23) into the housing. Tighten with the gland wrench (50) (50) and a
socketuntilushwiththehousing.
6. Reposition the housing in the vice with the inlet end upward.
7. For TU-20 models, insert the splined sleeve (2) into the housing with the groove trailing. Insert a 1”
square drive extension through the splined sleeve and into the end plug (20). Screw the end plug
into the splined sleeve until snug. Light lubrication on the spline sleeve will ease installation.
8. Wrap the swivel (39) (36)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).
9. Connect the tool to a pump and cycle several times to check for leaks.
10. 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.
11. Stake the thread of the gland and housing. Make certain the stake point deforms both the housing
and gland.
12. Wipeathinlmofmarinemolygreaseonthesidesofthedriveplate(13)(16) as well as the inner
race and piston rod recess of the drive plate.
13. Insert the ratchet (11) (14) into the drive plate (13) (16).
14. Position the drive segment (12) (15) at the cavity, ensuring the ratchet and drive segment engage
properly. If they will not engage properly, reverse the ratchet in the drive plate.
15. Insert the segment springs (26) (26) into the holes of the drive segment and compress while
installing the drive segment into the drive plate.
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.
NOTICE