REBUILD PROCEDURES: SERIES BCK1 CyLINDERSlitstore.phdinc.com/pdf.asp?filename=6441660.pdf3) Align...
Transcript of 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
MULTI-FUNCTIONIMPACT SEAL
CYLINDER TUBE
MUFFLER
MANIFOLD
MOUNTING PLATE
4X MOUNT PLT TOHEAD/CAP SHCS
4X SAFETY WASHER4X WASHER
MULTI-FUNCTIONIMPACT SEAL
HEAD
ROD BUSHINGROD SEAL
RETAINING RINGFLANGE
4X FLANGE TOHEAD SHCS
JAM NUT
HEAD ASSEMBLY
4X SHOULDER BOLTW / FEMALE THREAD
1/4 BSPPELBOW FITTING
POLYURETHANETUBING
PISTON & RODASSEMBLY
PISTON SEAL
WEAR RING
1/4 BSPPELBOW FITTING
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
MULTI-FUNCTIONIMPACT SEAL
COUNTERBORE
MULTI-FUNCTIONIMPACT SEAL FACE
TAMPER EVIDENT TAG(SEE NOTE 2)
CYLINDER TUBE
CYLINDER TUBE I.D.MULTI-FUNCTIONIMPACT SEAL O.D.
CAP
4X SHOULDER BOLTW / FEMALE THREAD
M8 HEX WRENCH
!
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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]
REBUILD PROCEDURES: SERIES BCK1 CyLINDERS
PART NO.: 6441-660C
3
PISTON & RODASSEMBLY
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
4X SHOULDER BOLTW / FEMALE THREAD
M8 HEX WRENCH
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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.
REBUILD PROCEDURES: SERIES BCK1 CyLINDERS
TORQUE CHaRT 1
PaRT DESCRIPTIONTORQUE
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
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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
PaRT DESCRIPTIONTORQUE
in-lb NmValve Manifold Fastener (M5) 120 [13.6]
Plate Fastener (M4) 80 [9.2]Flange Mounting Fasteners 200 [22.6]
REBUILD PROCEDURES: SERIES BCK1 CyLINDERS
PART NO.: 6441-660C
5
4X SHOULDER BOLTW / FEMALE THREAD
4X CYLINDER TO CAP SHCS
CAP
4X WASHER
4X SAFTEY WASHER
4X MOUNT PLT TO HEAD/CAP SHCS
MULTI-FUNCTIONIMPACT SEAL
CUSHION O-RING
RETRACTSHOCK PAD
PISTON & RODASSEMBLY
NUT
1/4 BSPPELBOW FITTING
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
BUSHING TO BODYO-RING SEAL
PLUG
PISTON SEAL
ID
CAUTION: UNDER SPRING
PRESSURE
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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 PROCEDURES: SERIES BCK2 CyLINDERS
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
MULTI-FUNCTIONIMPACT SEAL
COUNTERBORE
MULTI-FUNCTIONIMPACT SEAL FACE
TAMPER EVIDENT TAG(SEE NOTE 2)
LOCKING CYLINDERROD SEAL
BUSHING
BUSHING O-RING SEAL
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
REBUILD PROCEDURES: SERIES BCK2 CyLINDERS
PART NO.: 6441-660C
7
RETAINING RING
PLUG
RETAINING RING
ROD BUSHING
ROD SEAL
BUSHING TO BODYO-RING SEAL
SHOCK PAD
P & R ASSEMBLY
FHCS
ROD
PISTON
BUSHING TO BODYO-RING SEAL
SPRING
STOP TUBE
BODY ASSEMBLY
BODY
BREATHER VENT
PISTON SEAL
ID
FIGURE 6
FIGURE 7
LOCKING CYLINDERASSEMBLY
CAP ASSEMBLY
4X SHCS
M4 HEX WRENCH
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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
PaRT DESCRIPTIONTORQUE
in-lb NmFHCS for P&R Assembly 80 [9.0]
SHCS for locking Cylinder to Cap 40 [4.5]
REBUILD PROCEDURES: SERIES BCK2 CyLINDERS
PART NO.: 6441-660C
8
STRAIGHT FITTING
MUFFLERORIFICE DISK
JAM NUT
1/4 BSPPELBOW FITTING
POLYURETHANE TUBING
3/8 NPT ELBOW FITTING
POLYURETHANE TUBING
1/4 BSPPELBOW FITTING
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
18mm OPEN END WRENCH
19mm OPEN END WRENCH
11/16" OPEN END WRENCH
16mm 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
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA REGULATION 21CFR 178.3570
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
PaRT DESCRIPTIONTORQUE
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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5-07
1Fu
ll un
it de
scrip
tion
requ
ired
follo
wed
by
-H42
1074
345-
183
5902
2-00
5-1
8414
1-00
7-02
6105
4-10
2Fu
ll un
it de
scrip
tion
requ
ired
follo
wed
by
-H48
1083
421
8342
474
345-
135
8526
859
022-
006-
184
141-
008-
0261
054-
124
8687
361
734-
138
5
44
8
56
10
41 40L
40L40
K
40E
40A
40F
40B
40H
40D
40
40J
40J
40C
40G
40B
40BA
40AC
40AA
40AB
3A33E3D
3F
= LO
CTIT
E 24
2 TH
REA
D L
OCK
ER
= LU
BRIC
ANT
PER
FD
A
REG
ULA
TIO
N 2
1CFR
178
.357
0KE
yO
PTIO
NPa
RT N
UM
BER
28-U
19 (I
SO 2
Val
ve, C
onne
ctor
out
Top
)78
212
28-U
23 (I
SO 2
Val
ve, C
onne
ctor
out
Sid
e)83
392
33-R
13 (S
ee R
odey
e Ki
t Num
ber)
—
50FI
ittin
g Ad
apto
r86
873
5116
mm
Tub
e Fi
tting
6173
4-13
8
BCK2
KI
T D
ESCR
IPTI
ON
KIT
NU
MBE
RCO
LOR
CO
DE
Seal
Kit*
(Ret
ract
Loc
k Cy
linde
r Onl
y)-H
9004
*
Rep
air K
it* (R
etra
ct L
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