Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your Dorman 55200 Universal Control Cable. Designed for versatility, this multi-purpose control cable offers a reliable solution for various applications, including automotive, industrial, and commercial uses. Please read this manual thoroughly before proceeding with installation or operation to ensure proper function and safety.
Product Overview
The Dorman 55200 Control Cable is engineered for durability and broad applicability. It features a 1-3/4 inch chrome handle and a 7-foot length, making it suitable for a wide range of control cable repair or replacement needs. Its robust construction ensures long-lasting performance.
- High-Quality Construction: Manufactured from durable materials for extended service life.
- Versatile Design: Available in various styles, including twist-to-lock and push-pull mechanisms, with different lengths, diameters, and knob designs to suit specific requirements.
- Broad Application: Suitable for automotive, household, industrial, and commercial control functions.
Image 1: Dorman 55200 Universal Control Cable with 1-3/4 inch chrome handle. This image displays the coiled cable and the chrome handle assembly.
Safety Information
Always prioritize safety during installation and operation. Failure to follow these guidelines may result in injury or damage to property.
- Wear appropriate personal protective equipment (PPE), such as gloves and eye protection, during installation.
- Ensure the vehicle or equipment is turned off and secured before beginning any work.
- Verify that the cable length and type are appropriate for your specific application.
- Avoid routing the cable near hot or moving parts that could cause damage or interference.
- Do not overtighten fasteners, as this can strip threads or damage components.
- If you are unsure about any step, consult a qualified professional.
Package Contents
The Dorman 55200 package typically includes the following:
- Dorman 55200: Control Cable With 1-3/4 In. Chrome Handle, 7 Ft. Length
Note: Additional mounting hardware or specialized tools may be required depending on your specific installation.
Setup and Installation
The Dorman 55200 control cable is designed for universal fit, requiring adaptation to specific applications. The following steps provide a general guide for installation. Specific vehicle or equipment requirements may vary.
- Prepare the Installation Area: Ensure the area where the cable will be installed is clean, accessible, and free from obstructions. If replacing an existing cable, carefully remove the old cable, noting its routing and connection points.
- Determine Cable Routing: Plan the optimal path for the new cable, avoiding sharp bends, pinch points, and areas of high heat or friction. Ensure the cable has sufficient slack for full range of motion without binding.
- Mount the Handle: Secure the chrome handle assembly in the desired location. This typically involves drilling a hole of appropriate diameter and using the provided nut to fasten the handle securely.
- Route the Cable: Carefully feed the cable through its planned path. Use cable ties or clamps as necessary to secure the cable and prevent it from interfering with other components.
- Connect the Cable End: Attach the inner wire of the control cable to the component it will operate (e.g., carburetor linkage, latch mechanism). This may require cutting the inner wire to the correct length and securing it with a set screw or crimp fitting.
- Test Functionality: Once installed, operate the control handle through its full range of motion to ensure smooth and unrestricted movement of the connected component. Adjust cable tension or routing as needed.
- Final Inspection: Double-check all connections and mounting points for security. Ensure no part of the cable is rubbing or binding against other components.
Image 2: Dorman 55200 Universal Control Cable featuring a T-handle design. This image shows the cable coiled with the T-handle at one end.
Image 3: Another view of the Dorman 55200 Universal Control Cable with the chrome handle. This perspective highlights the cable's flexibility and the handle's attachment mechanism.
Operating Instructions
Once properly installed, the Dorman 55200 control cable operates by a simple push-pull or twist-to-lock mechanism, depending on the specific handle design. To engage the controlled function, pull the handle. To disengage or release, push the handle back into its original position. For twist-to-lock variants, pull the handle to the desired position and twist to secure it, then twist back and push to release.
- Ensure the cable moves freely without excessive force.
- Do not force the handle if resistance is encountered; investigate the cause of obstruction.
Maintenance
Regular maintenance helps ensure the longevity and reliable operation of your control cable.
- Inspection: Periodically inspect the entire length of the cable for signs of wear, fraying, kinks, or damage to the outer casing.
- Lubrication: Apply a suitable lubricant to the inner wire and outer casing ends where they enter the handle and the controlled component, especially in dusty or corrosive environments. This helps maintain smooth operation.
- Cleaning: Keep the cable and handle free from dirt, debris, and corrosive substances.
- Tightness: Check all mounting fasteners for tightness and re-secure if necessary.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Cable binds or is stiff to operate. | Incorrect routing, lack of lubrication, damaged casing, debris. | Check cable routing for sharp bends. Lubricate inner wire. Inspect casing for damage. Clean any debris. |
| Controlled component does not fully engage/disengage. | Improper cable length, incorrect adjustment, loose connection. | Verify cable length and adjust connection points. Ensure the inner wire is securely fastened. |
| Handle feels loose after installation. | Mounting nut is not sufficiently tightened. | Tighten the mounting nut securely. |
Specifications
| Feature | Detail |
|---|---|
| Model Number | 55200 |
| Brand | Dorman |
| Handle Type | Chrome Handle (1-3/4 In.) |
| Cable Length | 7 Ft. |
| Item Weight | 1.92 ounces |
| Special Features | Easy to Install |
Warranty and Support
Dorman products are manufactured to high-quality standards. For specific warranty information, please refer to the packaging or the official Dorman website. Dorman stands behind its products and offers technical support.
Technical Support: Every Dorman part is backed by Dorman's ASE Blue Seal Certified technical support team. For assistance with installation, troubleshooting, or product inquiries, please contact Dorman customer service through their official channels.
For more information, visit the Dorman Store on Amazon.