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--- pto [2007/08/31 20:20]
n5na
+++ pto [2018/10/29 00:06] (current)
n5na [PTO Rebuild Grease]
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 ====== PTO Repairs & Fixes ======
 ===== PTO Rebuild Tips & Links =====
+  *{{pto_rebuild.pdf|Ten-Tec PTO Rebuild Instructions}}
+<html><font size="2"><i>N1EU comments: 1)After disassembly, you will have two very small black plastic pieces: the wedge ("O") and the ramp ("G").  I almost thought they were plastic shrapnel that had broken off the pistol plastic.  The diagram does show enough for you to orient them properly and assemble them.  2)The only step I had real difficulty with was at the end of assembly - securing the nuts on the screws holding the end cap on.  There's more clearance on one side and I put that nut on first.  I then secured the PTO in a vise so I could push the other screw in to expose maximum number of threads.  I could then just barely get the 2nd nut on while holding with needle nose pliers.</i></font></html>
 **From the Ten-Tec Reflector May 7, 2002**
-I Just finished cleaning one of my Corsair II PTO's recently and I have a few thoughts regarding the process. Ten Tec sells a kit for approximately $20.00 if you want a complete set of new mechanical parts for the rebuild. However, most of the time simply cleaning the existing parts works fine and may give the same longevity results as replacing the parts, IMHO. I believe where the brass PTO shaft is held in place by three steel ball bearings in the front of the PTO is where most of the brass filings that impair performance are generated. It is my belief that after the shaft has worn some, it does not contribute as much debris from the filings and may last as long as a new kit, again, IMOH.  I have cleaned a number of PTO's over the last 5 years and they are all still going strong. I do this for a few friends and myself. I have 6 Corsair II's and they are all EXTREMLY EXCELLENT RIGs ! !
+I Just finished cleaning one of my Corsair II PTO's recently and I have a few thoughts regarding the process. Ten Tec sells a kit for approximately $20.00 if you want a complete set of new mechanical parts for the rebuild. However, most of the time simply cleaning the existing parts works fine and may give the same longevity results as replacing the parts, IMHO. I believe where the brass PTO shaft is held in place by three steel ball bearings in the front of the PTO is where most of the brass filings that impair performance are generated. It is my belief that after the shaft has worn some, it does not contribute as much debris from the filings and may last as long as a new kit, again, IMHO.  I have cleaned a number of PTO's over the last 5 years and they are all still going strong. I do this for a few friends and myself. I have 6 Corsair II's and they are all EXTREMLY EXCELLENT RIGs ! !
-The following are some suggestions with a little humor that may save you some grief as you rebuilt your unit. It is not difficult but can be a little tricky if you don't make a few notes. I do recommend purchasing the [[/data/pto_rebuild_kit.jpg|PTO Kit]] from Ten Tec as it is contains an excellent internal drawing of the PTO, a complete set of mechanical parts and some high viscosity grease, as well as reassembly instructions. Only $20.00 or so while supplies last; who knows if the parts will be available in 5 or 10 years.
+The following are some suggestions with a little humor that may save you some grief as you rebuilt your unit. It is not difficult but can be a little tricky if you don't make a few notes. I do recommend purchasing the PTO Kit from Ten Tec as it is contains an excellent internal drawing of the PTO, a complete set of mechanical parts and some high viscosity grease, as well as reassembly instructions. Only $20.00 or so while supplies last; who knows if the parts will be available in 5 or 10 years.
 To get the PTO out, you will need to take the front panel off to get to the screws in the front of the PTO. Don't try to cut corners here, just take the front panel completely off. Be careful to not scratch the FP when taking the mic hardware off. The meter leads go to a connector on the topside of the unit and can be disconnected there. This also gives you an opportunity to clean the 5 toggle type switches with a good cleaner such as DEOXIT. This is an excellent time to clean the front panel with all of the knobs out of the
@@ Line 23: / Line 27: @@
   -Put a sign on the front door letting the Jehovah Whiteness people know that you are already saved but both of your neighbors are HELL-Bound and need their help desperately. Your Neighbors may start cutting their grass at 5:30 AM on Saturday mornings to get back at you but your PTO will be working perfectly and you will be up anyway snagging a new DX contact.
   -Put the Cat, Dog, lizard and especially any annoying, loud birds outside. After thePTO has been reinstalled and the Corsair II is working great, leave the Bird outside; the Corsair II will surely work better as a result. I had an African Gray Parrot that liked to mimic CW during contest. This QRM was settled once the bird found a new and loving home. Hope the new owner liked sloppy, left footed CW.
-  -One of those magnets on a wand is handy if you happen to drop one of the steel ball bearings, springs or locking pin on the carpet. Sorry but the magnet will not help with the brass parts no matter how much you disagree with the laws of Physics. You will also need a #1 and 2 Phillips screwdriver, needle nose pliers, lots of low lent, shop towels. I like the blue ones from the Auto Stores. Other items needed are Q-tips, a small 1/4 inch open-ended wrench, 71% Isopropyl Alcohol. Don't clean the pistol or other plastic parts with the Alcohol just the metal items. I cleaned the Pistol and plastic parts with a Q-tip and a water moistened towel. You will need a few drops of Super Glue such as Radio Shack Future Glue, part number 64-2331. Ten Tec uses high viscosity axel grease such as Exxon's, Unirex N-2 and enough to do several PTO's comes with the Ten Tec kit. I prefer using 1 Synthetic Universal Grease from Mobil, bar code 71924 96102. This product is available from automotive stores for less than $5.00 for 12.5 ounces. This grease is optimized to minimize wear while working under very high temperatures and pressure. I can say that I have not observed any wear between parts using this product for several years and absolutely no CW chirp, at least chirp generated by the PTO.
+  -One of those magnets on a wand is handy if you happen to drop one of the steel ball bearings, springs or locking pin on the carpet. Sorry but the magnet will not help with the brass parts no matter how much you disagree with the laws of Physics. You will also need a #1 and 2 Phillips screwdriver, needle nose pliers, lots of low lint, shop towels. I like the blue ones from the Auto Stores. Other items needed are Q-tips, a small 1/4 inch open-ended wrench, 71% Isopropyl Alcohol. Don't clean the pistol or other plastic parts with the Alcohol just the metal items. I cleaned the Pistol and plastic parts with a Q-tip and a water moistened towel. You will need a few drops of Super Glue such as Radio Shack Future Glue, part number 64-2331. Ten Tec uses high viscosity axel grease such as Exxon's, Unirex N-2 and enough to do several PTO's comes with the Ten Tec kit. I prefer using 1 Synthetic Universal Grease from Mobil, bar code 71924 96102. This product is available from automotive stores for less than $5.00 for 12.5 ounces. This grease is optimized to minimize wear while working under very high temperatures and pressure. I can say that I have not observed any wear between parts using this product for several years and absolutely no CW chirp, at least chirp generated by the PTO.
   -There is a little locking pin that has to be removed and reinstalled in the PTO shaft. I use a worn, and very small diameter Allen wrench and the butt of ascrewdriver to tap the pin out. Just gentle tapping is all that is required and once the pin starts moving, it can be pulled out with needle nose pliers. To reinstall the pin GENTLY grip it with a small pair of wire cutters and once started, press the pin in place with a miniature pair of channel lock pliers.This is the worse part of the rebuild and isn't that bad.
@@ Line 35: / Line 39: @@
 ----
-Just one addition suggestion. Work in a tray with raised sides to slow down the rolling parts leaving.
+Just one additional suggestion. Work in a tray with raised sides to slow down the rolling parts leaving.
 , Jerry, K0CQ
@@ Line 75: / Line 79: @@
 , K3YD
 ----
-  *[[http://www.io.com/~n5fc/c21_pto.htm|N5ESE's Century 21 PTO Rebuild Page]]
+**November 27, 2007**
-  *[[http://www.k9ew.us/525_pto.htm|K9EW's Argosy 525 PTO Rebuild Page]]
-  *[[http://www.k9ew.us/515_pto.htm|K9EW's Argonaut 515 PTO Rebuild Page]]
-  *{{pto_rebuild.pdf|PTO Rebuild Instructions}}
-===== PTO Rebuild Grease =====
+Although the real cure has been mentioned numerous times over the last 15 years or so, this question periodically comes up.  The need is mostly to "re-lube" not rebuild, because the original grease has hardened and caused the vernier to slip. Needless labor is done when not necessary.
-**From the Ten-Tec Reflector June 20, 2000**
-Phil Wood Bicycle grease sold at bike stores makes the claim that it is good until the inclusion of dirt....   Over the years I have used this grease for PTO applications (and many other applications), and have never seen it to separate or harden with time like just about all the others.  Try it, you may like it !!
+  -Set TT PTO rig (all models) on it's back with front panel up.
+  -Using small allen wrench remove main tuning knob.
+  -Remove felts to expose the shaft entry point into PTO.
+  -Drip denatured alcohol into this entry point and turn outer and inner shafts until they free up.  Turn from end to end of range many times.
+  -After a few minutes apply Tri-Flow bicycle lubricant (Teflon based) to same area and turn shafts in same fashion.
+  -Replace felts and tuning knob.
+  -Don't expect shaft to freeze up ever again. (unless you store the rig in your attic for 20 years)  :-)
-Regards,  Ken  K5ID
+I have done this to no less than eight TT PTO sets over the years and the problem has never recurred.
-----
-I called a local fancy bike shop some time back looking for Phil Wood grease and was told they had it, but only in tubs.  They filled a 35mm film canister for me free.  That ought be enough of the stuff to re-grease 50 or more PTO's.
+Tri-Flow is available at most bicycle shops.
-It has been in 5 PTO's for only a year but sure did make them work smooth!
+Perry  w8au
-Regards, Mike  N4NT@chartertn.net
 ----
+**November 29, 2007**
-Phil Wood grease is indeed great stuff. In addition to being a great lubricant it is also water proof making it great for fishing gear or other exposed applications. The non-hardening nature of the formulation would make it ideal for PTOs. It is also inexpensive! Most bike shops can get it or it is available nationally from:
+I haven't seen this mentioned in any discussion of re-builds, so I guess I will.
-bikemail@nashbar.com
+Apart from the well-known "marble rolling through chewing gum" effect that the aging grease has on operation, there's one other thing I've noticed over years of repairs.  The little plastic thrust-bearing cup on the back side of the PTO box has a tendency to stress-relieve over time.  When this happens, the pressure on the shaft, along with the pressure the orbital balls should have against the race in the planetary drive, is reduced.  Loss of this pressure is what causes the drive to slip.  I have noticed, almost without exception, deformation on the "ears" of the thrust cups in afflicted PTOs.
-You can also reach Bike Nashbar by mail or phone.
+There are usually a couple of washers between the thrust cup and the PTO housing.  I move these from there, and put them under the heads of the #4 screws, so the pressure between the planetary bearings and the brass race increases, because the compression system is about .012" shorter.
-Bike Nashbar\\
+This is, of course, after all the old grease is removed and a suitable replacement lubricant is applied.
-Simon Rd\\
-Youngstown, Ohio 44512\\
--800-NASHBAR (1-800-627-4227)
-This is a well known mail order discount bike store. The main disadvantage is it is green and tends to stain.
+I've never seen deep grooves worn into the races.  Given the fact that the assembly is lubricated, I imagine it would take an enormous amount of use to do that, especially since the relatively soft plastic thrust cup is exerting all the pressure.
-Paul N. Henning
+Your mileage may vary.
-K9PH
-----
-[[http://www.philwood.com/phome.htm|Phil Wood Home Page]]
+\\
+Phil C. Sr.\\
+k4dpk
 ----
+  *[[https://web.archive.org/web/20050315152428/http://www.io.com:80/~n5fc/c21_pto.htm|N5ESE's Century 21 PTO Rebuild Page]]
+  *[[http://www.k9ew.us/525_pto.htm|K9EW's Argosy 525 PTO Rebuild Page]]
+  *[[http://www.k9ew.us/515_pto.htm|K9EW's Argonaut 515 PTO Rebuild Page]]
+  *{{pto_rebuild.pdf|Ten-Tec PTO Rebuild Instructions}}
+===== PTO Rebuild Grease =====
 **September 3, 2002**
@@ Line 135: / Line 145: @@
 ----
-[[http://kb.tentec.com/index.php?article=53|Ten-Tec Knowledge Base Article on PTO Grease]]
 ===== PTO Stabilizer Board =====
 **From the Ten-Tec Reflector February 17, 2005**
-I installed the VFO stabilizer found at: http://home.comcast.net/~k4dpk/pep_adapter.htm in my Corsair II. It works with TenTec 580, 540, Triton, Corsair, and Omni series.
+I installed [[https://www.qrz.com/db/k4dpk|K4DPK]] the VFO stabilizer in my Corsair II. It works with TenTec 580, 540, Triton, Corsair, and Omni series.
 This is a high quality board that has a look and feel similar to the boards that are used in the Corsair II. I mounted mine vertically along the case edge, just to the right of the .25 filter position, using an existing hole in the chassis.

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