PHD BCS2-6 Series Manual

THE PHD WARRANTY COVERS THE CYLINDER, ISO VALVE,
MANIFOLD AND ALL OTHER COMPONENTS ON THE CYLINDER
WITH THE EXCEPTION OF THE -X26 CHECK VALVE. THE CHECK
VALVE IS PROVIDED AS A SERVICE TO THE CUSTOMER, BUT
DOES NOT CARRY THE PHD WARRANTY.
®SERIES BCS2-6 STRETCHING CYLINDER
REBUILD PROCEDURES
These procedures include instruction for units with cushions.
P.O. Box 9070, Fort Wayne, IN 46899
1-800-624-8511
For additional technical assistance, call:
FIGURE 1
SHCS
MANIFOLD BLOCK
ASSEMBLY
MUFFLER
MUFFLER
STEEL TUBING
O-RING SEAL
MANIFOLD BLOCK
MANIFOLD TO
HEAD O-RING
SEAL
CAP ASSEMBLY
SHOULDER BOLT
W/ FEMALE THREAD
CAP
RETAINING RING
CUSHION NEEDLE
ASSEMBLY
MULTI-FUNCTION
IMPACT SEAL
CUSHION
O-RING SEAL
PISTON
SEAL
STEEL TUBING
O-RING SEAL
WEAR RING
PISTON SEAL
PISTON
PISTON & ROD
ASSEMBLY
STEEL TUBE
ROD CYLINDER
TUBE BORE
MULTI-FUNCTION
IMPACT SEAL
HEAD
ASSEMBLY
HEAD ROD BEARING
ROD SEAL
SHOULDER BOLT
W/ FEMALE THREAD
FLANGE
RETAINING
RING
FLANGE TO MANIFOLD
CAP SCREWS
JAM NUT
ROD EYE
FLANGE TO HEAD
CAP SCREWS
REBUILD/REASSEMBLY
1) Be careful to prevent cutting or damaging seals
during reassembly.
2) Use FDA Regulation 21CFR 178.3570 lubricant for
lubrication of air cylinders during reassembly.
3) Use FIGURE 1 for reference.
HEAD ASSEMBLY
A1) Press rod bearing into head, from end with snout, until flush as shown.
See FIGURE 2.
A2) Lubricate rod seal cavity and press in rod seal. Install retaining ring.
A3) Install multi-function impact seal in head.
!
Pre-lubricate rod seal cavity.
Pre-lubricate rod seal.
Insert rod seal into cavity.
Press rod bearing into head, from
end with snout, until flush as shown.
Lightly lubricate and install
multi-function impact
seal to head.
Caution: Over lubrication may cause cushion to malfunction.
TOOLS NEEDED:
Hex wrenches: M2.5, M4, M5, M6, and M8
Pliers
Small flat blade screwdriver
M24 open end or adjustable wrench
22 mm diameter pin or socket
(to press in rod bearing and rod seal)
Arbor press
20-250 in-lb torque wrench with
M2.5, M4, M5, M6 and M8 hex attachments
Press in rod seal.
PART NO.: 6441-503L
1
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA
REGULATION 21CFR 178.3570
A1 A2
After installing retaining ring, apply a small amount of
lubrication to inside of rod seal.
A3
DISASSEMBLY OF THE CYLINDER
1) WARNING: All air pressure in the unit must be
exhausted prior to disassembly of nozzle cylinder.
2) Remove valve from manifold (valve not shown).
3) Remove mufflers from manifold if necessary.
4) Remove check valve, fitting adaptor, and male run tee
from manifold/inlet adaptor. If -X25, -X26 or -X27
(inlet adaptor) is present, remove from manifold.
5) Remove flange, rod eye, and jam nut.
6) Remove cap, carefully slide cap away from tube as not
to bend steel tube.
7) Remove steel tube.
8) Remove manifold.
9) Remove head.
10) Slide piston rod assembly from cylinder tube.
11) Remove all seals, noting orientation (especially note
orientation of rod seal). Exercise caution to prevent
scratching of the sealing surfaces. See FIGURE 2.
12) Remove cushion needle assembly (these items are
sold in separate kits from the cylinder repair kit).
13) Clean and inspect all components. Excessively worn or
damaged components should be replaced.
14) Clean flange bearing bore shoulder with acetone to
remove adhesive.
FIGURE 2
ROD BEARING
RETAINING RING
ROD SEAL,
NOTE ORIENTATION
FLANGE HEAD
FLANGE BEARING
BORE SHOULDER
FILL GROOVE
IN THIS
LOCATION
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THE PHD WARRANTY COVERS THE CYLINDER, ISO VALVE,
MANIFOLD AND ALL OTHER COMPONENTS ON THE
CYLINDER WITH THE EXCEPTION OF THE -X26 CHECK VALVE.
THE CHECK VALVE IS PROVIDED AS A SERVICE TO THE
CUSTOMER, BUT DOES NOT CARRY THE PHD WARRANTY.
TORQUE CHART 1
FLANGE TO HEAD SHCS
FLANGE TO MANIFOLD SHCS
SHOULDER BOLT
-U19 OPTION VALVE ASSEMBLY
PISTON TO ROD
MANIFOLD SHCS
MUFFLER TO MANIFOLD ASSEMBLY
CHECK VALVE
FITTING ADAPTOR
INLET ADAPTOR TO MANIFOLD SHCS
PART DESCRIPTION TORQUE in-lb [Nm]
200 [22.6]
80 [9.0]
250 [28.2]
140 [15.8]
325 [36.7]
80 [9.0]
80 [9.0]
HAND TIGHTEN
PLUS 1/4 TURN
!
CAP ASSEMBLY TO TUBE
C1) Lubricate cushion seal and I.D. of tube at cap end. 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 impact seal and cap.
C2) Insert custom shoulder bolts through head. Tighten assemblies until they bottom out on counterbores
in head, then torque per CHART 1.
SERIES BCS2-6 STRETCHING CYLINDER REBUILD PROCEDURES
Insert custom shoulder bolts through head. Tighten
assemblies until they bottom out on counterbores in
head, then torque per CHART 1.
CAP ASSEMBLY
B1) Lightly lubricate cushion needle o-ring with oil and install cushion needle assembly
and retainer. Care should be taken to ensure retainer is properly installed to prevent
needle from backing out (cushion needle assembly and retainer are supplied as
part of cushion kit). See FIGURE 4.
B2) Install multi-function impact seal, retaining cushion seal between impact seal and cap.
Alignment of multi-impact seal is critical for cushions to properly function.
See FIGURE 4 for multi-function impact seal orientation.
B3) Install steel tube o-ring seal into cap. Press steel tube into cap with rotating motion.
NOTE:
Video tape #FM-CV1 is also available, covering repair procedures on Series CV Cylinders,
on which Series BCS Cylinder design is based.
Lubricate and place cushion seal. Retain cushion seal between
cap and impact seal. Be sure
impact seal is orientated to
align with orifice in cap.
Lightly lubricate
impact seal.
Install steel tube o-ring seal
into cap. Press steel tube into
cap with rotating motion.
Caution: Over lubrication may cause the cushion to malfunction.
PART NO.: 6441-503L
2
P.O. Box 9070, Fort Wayne, IN 46899
1-800-624-8511
For additional technical assistance, call:
C2
B2
B3
FIGURE 4 CAP EXPLODED VIEW
B1
TUBE O-RING SEAL
COMMUNICATION
TUBE
CUSHION ORIFICE MUST
ALIGN WITH ORIFICE IN
MULTIFUNCTION IMPACT SEAL
CUSHION SEAL
RETAINER
NEEDLE ASSEMBLY
CUSHION CONTROL
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FIGURE 5
PISTON SEALS
WEAR RING
PISTON AND ROD ASSEMBLY
LARGEST GROOVE
PISTON ROD ASSEMBLY AND
INSTALLATION INTO TUBE
D1) Lightly lubricate seals and tube, install onto piston. See FIGURE 5 for proper seal orientation.
D2) Lubricate piston grooves (filling the largest groove). See FIGURE 5 for correct groove location.
D3) Re-lubricate piston seals to assure uniform lubrication. Then apply light coat of lubrication to
cylinder bore at extend end of tube. Lubricate wear ring.
D4) Wrap wear ring around piston.
D5) Insert piston and rod assembly into cylinder bore. Tool may be required to compress lips of
seals to allow insertion. Be careful to prevent damage to seals during installation.
HEAD ASSEMBLY TO TUBE
E1) Lubricate rod end.
E2) Insert head onto rod, rotating head slightly to help rod through rod bearing and rod seal.
NOTE: Multi-function impact seal orientation with respect to head is not critical during this process.
E3) Align head squarely with tube and press head onto tube.
E4) Loosely thread custom shoulder bolts into head. Tighten assemblies until they bottom out on counterbores
in head, then torque per CHART 1.
SERIES BCS2-6 STRETCHING CYLINDER REBUILD PROCEDURES
Lightly lubricate seals and
tube, install onto piston. Lubricate piston grooves.
Re-lubricate piston seals
to ensure uniform lubrication.
Lubricate wear ring.
Then apply light coat of
lubrication to cylinder bore at
extend end of tube.
Wrap wear ring around piston. Insert piston and rod
assembly into
cylinder bore.
Lubricate rod end. Insert head onto rod, rotating head slightly to
help rod through rod bearing and rod seal.
Align head squarely with tube and press
head onto tube.
Loosely thread custom shoulder
bolts into head.
Tighten assemblies until they bottom out on
counterbores in head, then torque per CHART 1.
PART NO.: 6441-503L
3
P.O. Box 9070, Fort Wayne, IN 46899
1-800-624-8511
For additional technical assistance, call:
D1 D2
D3
D4 D5
E1 E2 - E3
E4
D3
D3
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MANIFOLD
F1) Lubricate o-ring and install it into end of manifold.
F2) Lubricate o-ring and attach it to spot face on manifold.
F3) Line up steel tube with end of manifold, with rotating motion, insert manifold onto steel tube.
F4) Fasten manifold onto head, then torque to CHART 1.
F5) Attach mufflers to manifold.
INLET ADAPTOR (-X25 OPTION)
G1) Lubricate both o-rings and attach to spot face on face of inlet adaptor.
G2) Line up bottom of inlet adaptor block with step in manifold.
G3) Fasten inlet adaptor to manifold, then torque
to CHART 1.
G4) Attach bleed off valve to inlet adaptor assembly,
then torque to CHART 1.
G5) Attach beather vent to end of bleed off valve, then
torque to CHART 2.
CHECK VALVE (-X26 OPTION)
NOTE: -X26 INCLUDES -X25
H1) Follow -X25 option then do following:
H2) Apply primer and hydraulic sealant to male thread (NPT end - long end) on BSPP to NPT
nipple and attach to inlet adaptor, then torque to CHART 1.
H3) Lubricate sealing ring with grease provided and install over BSPP thread of nipple.
H4) With undercut on check valve towards inlet adaptor, attach check valve to BSPP end of
nipple, then torque to CHART 1.
H5) Attach male run tee or elbow to check valve, then torque to CHART 1.
SERIES BCS2-6 STRETCHING CYLINDER REBUILD PROCEDURES
TORQUE CHART 1
FLANGE TO HEAD SHCS
FLANGE TO MANIFOLD SHCS
SHOULDER BOLT
-U19 OPTION VALVE ASSEMBLY
PISTON TO ROD
MANIFOLD SHCS
MUFFLER TO MANIFOLD ASSEMBLY
CHECK VALVE
FITTING ADAPTOR
BLEED OFF VALVE
BEATHER VENT
INLET ADAPTOR TO MANIFOLD SHCS
CAP TO INLET ADAPTOR SHCS
PART DESCRIPTION TORQUE in-lb [Nm]
200 [22.6]
80 [9.0]
250 [28.2]
140 [15.8]
325 [36.7]
80 [9.0]
80 [9.0]
125 [14.1]
Lubricate o-ring and install
it into end of manifold.
Attach mufflers to manifold.O-ring spot face
interface
Lubricate both o-rings and
attach to spot face on face
of inlet adaptor.
PART NO.: 6441-503L
-X25 option & -X26 option
(included in both options)
-X26 option
additional parts
30
33
16
39
31
17
18
SEE TORQUE CHART
FOR TORQUE SETTING
SEE NOTE 1
SEE NOTE 1
SEE NOTE 1
SEE NOTE 1
SEE NOTE 1
SEE NOTE 1
21
20
-X27 option
32
31
32
18
21
50
51
52
53
54
30
33
20
4
HAND TIGHTEN
PLUS 1/4 TURN
NOTE:
1) Kit does not include items 18, 20 & 21.
Must reuse existing components or replace separately.
= LOCTITE 242 THREAD LOCKER
= LUBRICANT PER FDA
REGULATION 21CFR 178.3570
P.O. Box 9070, Fort Wayne, IN 46899
1-800-624-8511
For additional technical assistance, call:
F1 F2 - F4 F5
G1
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SERIES BCS2-6 STRETCHING CYLINDER REBUILD PROCEDURES
PART NO.: 6441-503L
FINISH ASSEMBLY
J1) Attach flange to manifold with cap screws. Fasten flange to head with flange to head cap screws, then torque to CHART 1.
START-UP PROCEDURES
Standard units should be securely mounted with all fittings and external flow control
devices attached prior to applying pressure to unit. Care should be taken to provide
adequate space for rod to extend from unit. Apply pressure slowly to unit.
Cushion control should have cushion needle closed (turn needle clockwise until
rotation stops) and then opened one turn, prior to applying pressure to unit. This is not
necessary if load has not been attached to cylinder. (See Start-up Procedures sheet for
detailed instructions.)
Attach flange to manifold with cap screws.
Fasten flange to head with flange to head cap
screws, then torque to CHART 1.
CHECK VALVE (-X27 OPTION)
NOTE: REFER TO G1 THRU G5 FOR ADDITION ASSEMBLY PROCEDURES (Items 18, 20 & 21 not included in kit. Must be reused.)
I1) Lubricate and install quick exhaust seal, lip side down, into bore in inlet adaptor assembly.
I2) Lubricate and install o-ring seal onto boss on bottom of cap.
I3) Lubricate and install o-ring seal into counterbore on top of manifold assembly.
I4) Install cap boss into manifold assembly bore.
I5) Line up side of cap with side of inlet adaptor assembly, attach with 4X M5 SHCS, use removable adhesive,
then torque to CHART 1.
I6) Install male run tee fitting or elbow fitting, then torque to CHART 1.
5
P.O. Box 9070, Fort Wayne, IN 46899
1-800-624-8511
For additional technical assistance, call:
J1
I1 I2 I3
I4 I5 I6
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