rebuild procedures: series bck1 cylinderslitstore.phdinc.com/pdf.asp?filename=6441660.pdf3) align...

PART NO.: 6441-660C

1

FIGURE 2

FIGURE 3

ROD SEAL

ROD BUSHINGI.D.

RETAINING RING

HEAD

MULTI-FUNCTIONIMPACT SEAL

STRAIGHT FITTING2X MANIFOLD TO MOUNT PLT SHCSORIFICE DISK

2X SAFTEY WASHER2X WASHER

3/8 NPT ELBOW FITTING

CAP ASSEMBLY

4X SHOULDER BOLTW / FEMALE THREAD

CAP

RETRACTSHOCK PAD

CUSHION O-RING


CYLINDER TUBE

MUFFLER

MANIFOLD

MOUNTING PLATE

4X MOUNT PLT TOHEAD/CAP SHCS

4X SAFETY WASHER4X WASHER


HEAD

ROD BUSHINGROD SEAL

RETAINING RINGFLANGE

4X FLANGE TOHEAD SHCS

JAM NUT

HEAD ASSEMBLY


1/4 BSPPELBOW FITTING

POLYURETHANETUBING

PISTON & RODASSEMBLY

PISTON SEAL

WEAR RING


ROD BEARING SNOUT

RETAININGRING

ROD SEALORIENTATION

FLANGE HEADROD BEARINGBORE SHOULDER

I.D.

= LOCTITE 242 THREAD LOCKER

= LUBRICANT PER FDA REGULATION 21CFR 178.3570

KIT DESCRIPTION KIT NUMBER COLOR CODE

Seal Kit* -H9000*

Repair Kit* -H9010*

Rod Eye Mounting Kit 52493-03-1

NOTE: *Full unit description required (followed by -Hxxxx)

DISaSSEMBLy OF THE CyLINDER1) WaRNING: All air pressure in the unit must be

exhausted prior to disassembly of stretch rod cylinder.2) Remove valve from manifold (valve not shown).3) Remove mufflers, fittings and orifice disk from

manifold if necessary.4) Remove manifold from manifold mounting plate.5) Remove flange and jam nut.6) Remove polyurethane tubes.7) Remove fittings from head and cap.8) Remove shoulder bolt fasteners retaining

head and cap.9) Remove head and cap.10) Slide piston rod assembly from cylinder tube.11) Remove all seals, noting orientation. Exercise

caution to prevent scratching of the sealing surfaces. See Figure 2.

12) Clean and inspect all components. Excessively worn or damaged components should be replaced.

REBUILD/REaSSEMBLy OF THE CyLINDER1) PHD recommends using Loctite® 242 thread locker

on all threaded fasteners.2) Be careful to prevent cutting or damaging seals

during reassembly.3) Use FDA Regulation 21CFR 178.3570 lubricant for

lubrication of air cylinders during reassembly.

SEE 6441-659 STaRT-UP aND INFORMaTION SHEET FOR CyLINDER INSTaLLaTION aND aLIGNMENT PROCEDURES.

HEaD aSSEMBLy1) Press rod bushing into head, from end with snout,

until seated as shown.2) Lubricate rod seal cavity and press in rod seal.3) Install retaining ring.4) Lightly lubricate and install multi-function impact seal

in head.

REBUILD PROCEDURES: SERIES BCK1 CyLINDERS

TOOLS NEEDED:- Hex wrenches: M4, M5, M6, and M8- Pliers- Small flat blade screwdriver- Open end or adjustable wrench- 22 mm diameter pin or socket (to press

in rod bearing and rod seal)- Arbor press- 80-250 in-lb torque wrench with M4,

M5, M6 and M8 hex attachments

PART NO.: 6441-660C

2

FIGURE 5

(10°)

(10°) MULTI-FUNCTION SEAL ORIFICE

CUSHION ORIFICE

FIGURE 4

CUSHION ORIFICE

MULTI-FUNCTION SEAL ORIFICE

CAP

RETRACTSHOCK PAD

CUSHION O-RING


COUNTERBORE

MULTI-FUNCTIONIMPACT SEAL FACE

TAMPER EVIDENT TAG(SEE NOTE 2)

CYLINDER TUBE

CYLINDER TUBE I.D.MULTI-FUNCTIONIMPACT SEAL O.D.

CAP


M8 HEX WRENCH

!





CaP aSSEMBLy1) Lightly lubricate and install retract shock pad into bottom of

counterbore in cap, press until seated. (NOTE ORIENTATION)2) Lubricate and place cushion o-ring seal onto multi-function impact

seal face in cap.3) Lightly lubricate and install multi-function impact seal in cap,

trapping the cushion o-ring seal between the multi-function impact seal and the multi-function impact seal face. Alignment of multi-impact seal is critical for cushions to properly function.

CaUTION: Over lubrication may cause the cushion to malfunction.

CaP TO TUBE aSSEMBLy1) Lubricate multi-function impact seal O.D. and I.D. of tube at cap end.2) Align cap squarely with tube and press cap onto tube. Do not rotate

cap with respect to tube during this process. This could cause misalignment of orifices in the impact seal and cap.

3) Insert custom shoulder bolts through head. Tighten assemblies until they bottom out on counterbores in head, then torque per CHART 1.

NOTE 2:a tamper evident tag is placed over the cushion control needle cavity, removal of the tag and/or adjustment of the cushion needle will void the warranty of the BCK cylinder.

TORQUE CHaRT 1

PaRT DESCRIPTIONTORQUE

in-lb NmShoulder Bolt w/ Female Thread 250 [28.2]


PART NO.: 6441-660C

3


PISTON SEAL

CYLINDER TUBE

WEAR RING

PISTON SEAL

PISTON & ROD ASSEMBLY WITHWEAR RING AND SEALS INSTALLED

PISTON SEAL

WEAR RING

LARGESTGROOVE

CYLINDER TUBE I.D.

EVENLY DISTRIBUTE LUBE

CYLINDER TUBE

ROD END

HEAD ASSEMBLY


M8 HEX WRENCH



PISTON ROD aSSEMBLy aND INSTaLLaTION INTO TUBE1) Lightly lubricate seals, install onto piston.2) Apply light coat of lubrication to cylinder bore at extend end of tube.3) At largest groove, lubricate wear ring and wrap around piston.4) Insert piston and rod assembly into cylinder bore.NOTE: Tool may be required to compress lips of seals to allow insertion. Be careful to

prevent damage to seals during installation.

HEaD aSSEMBLy TO TUBE1) Lubricate rod end.2) Insert head onto rod, rotating head slightly to help rod through rod

bearing and rod seal.NOTE: Multi-function impact seal orifice orientation with respect to head

is not critical during this process.3) Align head squarely with tube and press head onto tube.4) Loosely thread custom shoulder bolts into head. Tighten assemblies

until they bottom out on counterbores in head, then torque per Chart 1.


TORQUE CHaRT 1


in-lb NmShoulder Bolt w/ Female Thread 250 [28.2]

PART NO.: 6441-660C

4

4X PLATE FASTENER

4X SAFTEY WASHER

4X WASHER

SLOTS

HEAD

CAP

THREADEDHOLES

MOUNTING PLATE

2X VALVE MANIFOLDFASTENER

2X SAFTEY WASHER

2X WASHER

CYLINDER

4X FLANGE MOUNT FASTENER

FLANGE

HEAD

MOUNTINGPLATE

M6 HEX WRENCH

M5 HEX WRENCH

M4 HEX WRENCH



MOUNTING PLaTE TO HEaD/CaP1) Place mounting plate onto head and cap, align slots

and through holes with threaded holes.2) Install 4X fasteners into head and cap.3) Torque mount plate to head/cap SHCS to Chart 1.

MaNIFOLD TO MOUNTING PLaTE1) Place manifold onto mounting plate as shown, align holes in

manifold with threads.2) Loosly install SHCS through both saftey washer and washer.3) Align manifold to be perpendicular to mounting plate.4) Install 2X fastener thru manifold and thread into mounting plate.5) Torque manifold to mount plate SHCS to Chart 1.

FLaNGE TO HEaD1) Place flange onto head as shown.2) Loosly install SHCS through flange into head.3) Align flange edge to be perpendicular to cylinder.4) Torque flange to head SHCS to Chart 1.

TORQUE CHaRT 1


in-lb NmValve Manifold Fastener (M5) 120 [13.6]

Plate Fastener (M4) 80 [9.2]Flange Mounting Fasteners 200 [22.6]


PART NO.: 6441-660C

5


4X CYLINDER TO CAP SHCS

CAP

4X WASHER

4X SAFTEY WASHER

4X MOUNT PLT TO HEAD/CAP SHCS


CUSHION O-RING

RETRACTSHOCK PAD


NUT


WEAR RING

PISTON SEAL

LOCKING CYLINDER

LOCKING CYLINDERROD SEAL

BUSHING

BUSHING O-RING SEALRETAINING RING

RETAINING RING

ROD BUSHING

ROD SEAL

CAP ASSEMBLY

BUSHING TO BODYO-RING SEAL

SHOCK PAD

P & R ASSEMBLY

FHCS

ROD

PISTON

BODY ASSEMBLY

BREATHER VENT

BODY

STOP TUBE

SPRING


PLUG

PISTON SEAL

ID

CAUTION: UNDER SPRING

PRESSURE



LOCKING CyLINDER DISaSSEMBLyA1) WaRNING: All air pressure in the unit must be exhausted prior to disassembly of nozzle cylinder.A2) NOTE: If only the retract lock portion of the cylinder is being repaired/rebuilt, removal of the cap and main P&R

assembly would not need to be performed. If complete cylinder repair/rebuild is being preformed, see BCK1 for all other disassembly procedures not covered on this page.

A3) Remove locking cylinder from cap.A4) Remove cap assembly from end of unit.A5) Remove bushing from cap.A6) Remove rod bushing and plug from locking cylinder. CaUTION: Take care when removing the plug, it is under spring pressureA7) Remove spring and stop tube from body.A8) Remove P & R assembly from body.A9) Remove all seals, noting orientation (especially note orientation of rod seals). Exercise caution to prevent

scratching of the sealing surfaces. See Figure 2.A10) Clean and inspect all components. Excessively worn or damaged components should be replaced.


REBUILD/REaSSEMBLy OF THE CyLINDER1) PHD recommends using Loctite® 242 thread locker on all threaded fasteners.2) PHD recommends using food grade lubrication on metal-to-metal contact points.3) Be careful to prevent cutting or damaging seals during reassembly.4) Use FDA Regulation 21CFR 178.3570 lubricant for lubrication of air cylinders

during reassembly.

TOOLS NEEDED:- Hex wrenches: M4, M5, M6, and M8- Pliers- Small flat blade screwdriver- Open end or adjustable wrench- 22 mm diameter pin or socket (to press

in rod bearing and rod seal)- Arbor press- 80-250 in-lb torque wrench with M4,

M5, M6 and M8 hex attachments

PART NO.: 6441-660C

6

LOCKING CyLINDER CaP aSSEMBLyB1) Lightly lubricate and install retract shock pad into bottom of counterbore in cap,

press until seated.B2) Lubricate and place cushion o-ring seal onto multi-function mpact seal face in cap.B3) Lightly lubricate and install multi-function impact seal in cap, trapping the cushion

o-ring seal between the multi-function impact seal and the multi-function impact seal face. Alignment of multi-impact seal is critical for cushions to properly function.

B4) Lightly lubricate and install the locking cylinder rod seal into the bushing.B5) Lightly lubricate and install the bushing o-ring seal onto the bushing.B6) Lightly lubricate the OD and ID of the bushing and install it into the cap until seated.CaUTION: Over lubrication may cause the cushion to malfunction.

NOTE 2:a tamper evident tag is placed over the cushioncontrol needle cavity, removal of the tag and/oradjustment of the cushion needle could void thewarranty of the BCK cylinder.

10°

10° MULTI-FUNCTION SEAL ORIFICE

CUSHION ORIFICE

FIGURE 4

FIGURE 5

CUSHION ORIFICE

MULTI-FUNCTION SEAL ORIFICE

CAP

RETRACTSHOCK PAD

CUSHION O-RING


COUNTERBORE

MULTI-FUNCTIONIMPACT SEAL FACE

TAMPER EVIDENT TAG(SEE NOTE 2)

LOCKING CYLINDERROD SEAL

BUSHING

BUSHING O-RING SEAL




PART NO.: 6441-660C

7

RETAINING RING

PLUG

RETAINING RING

ROD BUSHING

ROD SEAL


SHOCK PAD

P & R ASSEMBLY

FHCS

ROD

PISTON


SPRING

STOP TUBE

BODY ASSEMBLY

BODY

BREATHER VENT

PISTON SEAL

ID

FIGURE 6

FIGURE 7

LOCKING CYLINDERASSEMBLY

CAP ASSEMBLY

4X SHCS

M4 HEX WRENCH



CAUTION: UNDER SPRING

PRESSURE

CAUTION: SPRING MUST BEINSTALLED WITHTAPER OF SPRING

AS SHOWN

M4 HEX WRENCH

LOCKING CyLINDER aSSEMBLyC1) If required, attach piston to rod using FHCS and torque as specified in chart.C2) Lubricate and place piston seal onto piston, slip shock pad onto rod and set

against piston.C3) Lightly lubricate and install bushing to body o-ring seal into second groove in

each end of body.C4) Lubricate and install the rod seal into the bushing, note orientation (see Figure 6).C5) Install retaining ring into first groove in body to secure bushing.C6) Lightly lubricate outer edge of bushing and install the bushing into the body

until seated, note orientation (see Figure 6).C7) Insert P & R Assembly into body, through rod bushing and and rod seal.C8) Slip stop tube into body and place spring into inside diameter of stop tube in

direction shown (see Figure 6).C9) Lightly lubricate outer edge of plug and install into the body until seated.C10) While pushing down on the plug, install retaining ring into first groove in body

to secure plug.C11) Orient the assembled locking cylinder as shown (see Figure 7) and secure to the

cap assembly with 4 SHCS and torque as specified in chart.C12) Assemble cap assembly to main cylinder tube per standard BCK procedures.

TORQUE CHaRT 1


in-lb NmFHCS for P&R Assembly 80 [9.0]

SHCS for locking Cylinder to Cap 40 [4.5]


PART NO.: 6441-660C

8

STRAIGHT FITTING

MUFFLERORIFICE DISK

JAM NUT


POLYURETHANE TUBING

3/8 NPT ELBOW FITTING

POLYURETHANE TUBING


ROD END THREAD

MANIFOLD

HEAD

CAP

-U23 OPTIONAL VALVE

Ø 16 mm STRAIGHTS FITTING

FITTING ADAPTOR

-L2116 FITTINGOPTION

-U19 OPTIONAL VALVE

VALVE FASTENERS

- R13 OPTIONAL ROD EYE(HAND TIGHTEN)

SECURE WITH LOCK NUTAFTER MACHINE INSTALLATION

AND ADJUSTMENT.

16mm OPEN END WRENCH



11/16" OPEN END WRENCH


M5 HEX WRENCH

SOLENOID FASTENERS

VALVE FASTENERS

WHEN ATTACHING THE -U23 OPTION TO THECYLINDER MANIFOLD, THE TWO M3 SHCS THATHOLD THE SMALL MANIFOLD BLOCK TO THEVALVE BODY MUST BE REMOVED IN ORDER TOPROPERLY TORQUE THE M6 SHCS THAT ISUNDER THE SMALL MANIFOLD. IF THE M6SHCS IS NOT PROPERLY TORQUED, THE VALVEMAY LEAK AND THE M6 SHCS WILL DAMAGEBOTH THE SMALL MANIFOLD AND VALVE BODY.

SMALL MANIFOLD BLOCK

M5HEX WRENCH

M2.5HEX WRENCH



FINaL aSSEMBLy aND OPTIONaL aSSEMBLy1) Install orifice disk into manifold port 5, seat to bottom of threads.2) Thread in mufflers into manifold ports 3 and 5.3) Install straight fitting into manifold between

mufflers, port 1.NOTE: If -L2116 option, install adaptor then install the

Ø 16 mm straight fitting.4) Install 3/8 NPT elbow fittings into manifold In ports 2 and 4.5) Install 1/4 BSPP elbow fittings into head and cap in cylinder.6) Attach polyurethane tubing, running from the

1/4 BSPP fitting to the 3/8 NPT fitting.7) Attach jam nut to rod end thread.8) If applicable, attach valve to manifold as shown.9) If applicable, attach rod eye to end of rod as shown.10) Torque above components as specified in Chart 1.

SEE 6441-659 STaRT-UP aND INFORMaTION SHEET FOR CyLINDER INSTaLLaTION aND aLIGNMENT PROCEDURES.

TORQUE CHaRT 1


in-lb NmMuffler 227 [25.6]

Straight Fitting 227 [25.6]Elbow Fitting - Head/Cap 90 [10.2]Elbow Fitting - Manifold 227 [25.6]

Valve Fastener (M5) 140 [15.8]Fitting Adaptor 227 [25.6]

Solenoid Fasteners 20 [2.3]Fitting Adaptor 227 [25.6]

REBUILD PROCEDURES: SERIES BCK1 & 2 CyLINDERS

PART NO.: 6441-660C

9

REBUILD PROCEDURES: SERIES BCK CyLINDERS

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ock

Cylin

der O

nly)

-H90

14*

NO

TE: *

Full

unit

desc

riptio

n re

quire

d (f

ollo

wed

by

-Hxx

xx)

NO

TES:

1) A

tam

per e

vide

nt ta

g is

pla

ced

over

the

cush

ion

cont

rol n

eedl

e ca

vity

. Rem

oval

of t

he ta

g an

d/or

adj

ustm

ent o

f the

cus

hion

nee

dle

will

voi

d th

e w

arra

nty

of th

e cy

linde

r.2)

CaU

TIO

N: W

hen

atta

chin

g th

e -U

23 o

ptio

n to

the

cylin

der m

anifo

ld (2

1), t

he tw

o M

6 SH

CS

that

hol

d th

e pi

lot b

lock

to th

e va

lve

body

mus

t be

rem

oved

in o

rder

to p

rope

rly a

ttach

the

valv

e to

the

man

ifold

. If t

he M

6 SH

CS a

re n

ot p

rope

rly to

rque

d, th

e va

lve

may

leak

and

the

SHCS

will

dam

age

both

the

pilo

t blo

ck a

nd th

e va

lve

body

.

!

!

BCK2

BCK1

BCK1

& B

CK2

KIT

DES

CRIP

TIO

NKI

T N

UM

BER

COLO

R

COD

E

Seal

Kit*

(Mai

n Cy

linde

r Onl

y)-H

9000

*

Rep

air K

it* (M

ain

Cylin

der O

nly)

-H90

10*

Rod

Eye

Mou

ntin

g Ki

t52

493-

03-1

CaU

TIO

N:

UN

DER

SP

RIN

GPR

ESSU

RE

rebuild procedures: series bck1 cylinderslitstore.phdinc.com/pdf.asp?filename=6441660.pdf3) align...

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