•
URL:
http://www
.tolomatic.com
•
Email:
[email protected] •
Fax:
(763)
478-8080
•
T
oll
Free:
1-800-328-2174
2 – General Installation and Maintenance Instructions CC50 Parts Sheet #1001-4006_04
INSTALLATION
When unpacking a Tolomatic cable cylinder, BE EXTRA CAREFUL NOT
TO SCRATCH OR MAR THE NYLON COVERING ON THE CABLE. The
cylinder may be mounted using the bolt holes in the head. When attaching
the cable bracket to the driven mechanism, be sure it is in perfect alignment
and that it does not deflect the cable to the side. Misalignment can cause
excessive wear.
Pretensioning and proof-loading instructions: All double-acting cable
cylinders are shipped without being pretensioned. They must be preten-
sioned after mounting to insure maximum service life of the device. There
are two types of stretch in cable— constructional and elastic. The construc-
tional stretch is removed by proof-loading of the cable. The elastic stretch is
removed by proper pretensioning of the cable.
Proof-loading of cables (for cylinders without Auto Tensioners):
1. Tighten the bracket terminal lock nuts equally with a torque
wrench to torque requirements listed in Table A.
2. Let set for 30 seconds.
3. Loosen lock nuts to remove tension. (But leave them tight
enough to eliminate any slack.)
4. Follow Pretensioning Instructions.
TABLE A: TORQUE TO PROOF-LOAD THE CABLE
MODEL REQUIRED TORQUE
CC50 325 inch-pounds OR 36.72 Newton-meters
Pretensioning of cables:
1. Block the load some distance from the end of travel to keep cyl-
inder from bottoming.
2. Apply pressure that is 15-20 percent higher than actual load
pressure needed to move the load.
NOTE: When the load is stopped externally before the piston bot-
toms, the relief valve or regulator setting becomes the load pres-
sure.
WARNING: The CC50 cable cylinder develops up to 1919
pounds of force at 100 PSI. Be certain the materials used to
block the load are sufficient to withstand these forces.
When pressurized, one cable becomes tight and the other
becomes slack. Manually adjust out the slack. Release the pres-
sure. Block the load on the opposite side and pressurize the
other port. Repeat the manual adjustment on the other cable.
Release pressure and remove blocks. Return the regulator or
relief valve to the original load pressure.
The cylinder is now pretensioned. Additional manual adjustment
should not be required. It is suggested however, that the cables be
checked periodically.
Alternate Method: If the load cannot be blocked for cable preten-
sioning as stated above, tighten the bracket terminal lock nuts with
a torque wrench to total pretensioning torque as stated in Table B.
TABLE B
Pretensioning + Starting Torque of = Total
Model Torque Terminal Nuts Pretensioning Torque
CC50 180.0 in-lbs. + 30.0 in.-lbs. = 210.0 in.-lbs.
20.34 N-m + 3.38 N-m = 23.72 N-m
NOTE: For cylinders with Auto Tensioners, the cables must be proof-load-
ed and pretensioned before pressure is applied to the AT unit.
TO REBUILD THE CYLINDER
1. Remove cylinder from machinery.
2. Disconnect Cable (21) from the Clevis (17) and remove Pulleys (14)
on both ends of the cylinder.
3. Remove internal retaining rings (2) from both heads and remove one
head from cylinder by removing the four Socket Head Cap Screws
(18)
4. Pull Piston (9) towards the opened tube end and remove from Tube
(6).
5. Disconnect Cables (21) from Piston (9) and pull back through the
Heads (11) with their Gland Seals (3) to remove them.
6. Install new U-cups (8) and O-rings (4) on piston (9) and rethread new
Cables (21) through Heads (11), and connect them to the Piston (9).
7. Being careful not to damage the cable, lubricate and install the Gland
Seals (3) in the Heads (11), and reinstall the retaining rings (2).
8. Push the piston back into tube by gently tucking in the U-cup (8) with a
screwdriver or pencil. Mount head back on cylinder with socket head
cap screws (18). Replace the Pulleys (14) and connect cable (21) to
the clevis (17).
9. Operate cylinder back and forth by hand several times to be sure it is
properly assembled before reconnecting air or hydraulic service.
10. Reinstall cylinder on machinery.
IMPORTANT NOTE: Apply (Blue) Loctite® #242 or equivalent to threaded
cable terminal before connecting to the piston.
MAINTENANCE
Keep the cylinder as clean as possible around pulleys, glands, etc.
Pneumatic service should be adequately lubricated with SAE 10 or 20
grade non-detergent oil.
Pulleys have permanently lubricated bearings and will require no mainte-
nance. Check the cylinder’s cables periodically to help prevent premature or
unexpected failures.
Your Tolomatic Cable Cylinder will give you many cycles of trouble free ser-
vice. However, should a leak occur, a rebuilding kit may be obtained which
enables you to replace all the seals in a cylinder to return it to normal oper-
ating condition.
