PART NO.: 6441-503K

®

SERIES BCS2-6-50 STRETCHING CYLINDER REBUILD PROCEDURES

These procedures include instruction for units with cushions.

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. SHOULDER BOLT W/ FEMALE THREAD

FIGURE 1

SHCS

DISASSEMBLY OF THE CYLINDER

ROD EYE MANIFOLD BLOCK ASSEMBLY

MANIFOLD BLOCK

FLANGE TO MANIFOLD CAP SCREWS

MUFFLER STEEL TUBING O-RING SEAL

MUFFLER MANIFOLD TO HEAD O-RING SEAL

1) Be careful to prevent cutting or damaging seals during reassembly. 2) Use FDA food grade lubricant for lubrication of air cylinders during reassembly. 3) Use FIGURE 1 for reference. Caution: Over lubrication may cause cushion to malfunction.

FLANGE TO HEAD CAP SCREWS

HEAD ASSEMBLY

FLANGE SHOULDER BOLT W/ FEMALE THREAD

STEEL TUBE ROD SEAL

STEEL TUBING O-RING SEAL

HEAD

PISTON

PISTON SEAL

PISTON & ROD ASSEMBLY

CUSHION O-RING SEAL

ROD BEARING

MULTI-FUNCTION IMPACT SEAL ROD

CYLINDER TUBE BORE FILL GROOVE IN THIS LOCATION

PISTON SEAL WEAR RING MULTI-FUNCTION IMPACT SEAL

= THREAD LOCKER

RETAINING RING CAP CAP ASSEMBLY

= FOOD GRADE GREASE

CUSHION NEEDLE ASSEMBLY

FIGURE 2

TOOLS NEEDED:

REBUILD/REASSEMBLY

JAM NUT

RETAINING RING

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

ROD BEARING

RETAINING RING

ROD SEAL, NOTE ORIENTATION FLANGE BEARING BORE SHOULDER

FLANGE HEAD

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.

A1

Pre-lubricate rod seal.

Press in rod seal.

Insert rod seal into cavity.

A3

Press rod bearing into head, from end with snout, until flush as shown.

A2 Pre-lubricate rod seal cavity.

After installing retaining ring, apply a small amount of lubrication to inside of rod seal.

!

For additional technical assistance, call:

Lightly lubricate and install THE PHD WARRANTY COVERS THE CYLINDER, ISO VALVE, multi-function impact MANIFOLD AND ALL OTHER COMPONENTS ON THE CYLINDER seal to head. 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.

1

P.O. Box 9070, Fort Wayne, IN 46899

1-800-624-8511

PART NO.: 6441-503K

SERIES BCS2-6-50 STRETCHING CYLINDER REBUILD PROCEDURES 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.

FIGURE 4

COMMUNICATION TUBE

CUSHION CONTROL

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.

B3

Lightly lubricate impact seal.

CUSHION ORIFICE MUST ALIGN WITH ORIFICE IN MULTIFUNCTION IMPACT SEAL

NEEDLE ASSEMBLY RETAINER

Caution: Over lubrication may cause the cushion to malfunction.

B2

CAP EXPLODED VIEW CUSHION SEAL TUBE O-RING SEAL

B1

Retain cushion seal between cap and impact seal. Be sure impact seal is orientated to align with orifice in cap.

Install steel tube o-ring seal into cap. Press steel tube into cap with rotating motion.

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.

C2

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

TORQUE CHART 1 PART DESCRIPTION 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

TORQUE in-lb [Nm] 200 [22.6] 80 [9.0] 250 [28.2] 140 [15.8] 325 [36.7] 80 [9.0] HAND TIGHTEN PLUS 1/4 TURN 80 [9.0]

! 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.

2

PART NO.: 6441-503K

SERIES BCS2-6-50 STRETCHING CYLINDER REBUILD PROCEDURES PISTON ROD ASSEMBLY AND INSTALLATION INTO TUBE

FIGURE 5 PISTON AND ROD ASSEMBLY

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.

PISTON SEALS

LARGEST GROOVE

WEAR RING

D1

Lightly lubricate seals and tube, install onto piston.

D2

Lubricate piston grooves.

D3

D3

Then apply light coat of lubrication to cylinder bore at extend end of tube.

D3

Lubricate wear ring.

Re-lubricate piston seals to ensure uniform lubrication.

D4

Wrap wear ring around piston.

D5

Insert piston and rod assembly into cylinder bore.

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.

E1

Lubricate rod end.

E4

Loosely thread custom shoulder bolts into head.

E2 - E3

Tighten assemblies until they bottom out on counterbores in head, then torque per CHART 1.

3

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.

PART NO.: 6441-503K

SERIES BCS2-6-50 STRETCHING CYLINDER REBUILD PROCEDURES MANIFOLD F1) F2) F3) F4) F5)

Lubricate o-ring and install it into end of manifold. Lubricate o-ring and attach it to spot face on manifold. Line up steel tube with end of manifold, with rotating motion, insert manifold onto steel tube. Fasten manifold onto head, then torque to CHART 1. Attach mufflers to manifold.

F1

Lubricate o-ring and install it into end of manifold.

F2 - F4

O-ring spot face interface

F5

TORQUE CHART 1 TORQUE in-lb [Nm] PART DESCRIPTION FLANGE TO HEAD SHCS 200 [22.6] FLANGE TO MANIFOLD SHCS 80 [9.0] SHOULDER BOLT 250 [28.2] -U19 OPTION VALVE ASSEMBLY 140 [15.8] PISTON TO ROD 325 [36.7] MANIFOLD SHCS 80 [9.0] MUFFLER TO MANIFOLD ASSEMBLY CHECK VALVE HAND TIGHTEN FITTING ADAPTOR PLUS 1/4 TURN BLEED OFF VALVE BEATHER VENT INLET ADAPTOR TO MANIFOLD SHCS 80 [9.0] CAP TO INLET ADAPTOR SHCS 125 [14.1]

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.

-X25 option & -X26 option (included in both options) SEE NOTE 1 21 20

G1

SEE NOTE 1

Lubricate both o-rings and attach to spot face on face of inlet adaptor.

30

-X27 option

31 32

SEE NOTE 1

21 20

SEE NOTE 1

-X26 option additional parts

16 50

33

39

SEE TORQUE CHART FOR TORQUE SETTING

17

51

18 52

SEE NOTE 1

53

SEE NOTE 1

54

18

30

CHECK VALVE (-X26 OPTION)

31

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.

4

32 33

NOTE: 1) Kit does not include items 18, 20 & 21. Must reuse existing components or replace separately.

PART NO.: 6441-503K

SERIES BCS2-6-50 STRETCHING CYLINDER REBUILD PROCEDURES 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) I2) I3) I4) I5)

Lubricate and install quick exhaust seal, lip side down, into bore in inlet adaptor assembly. Lubricate and install o-ring seal onto boss on bottom of cap. Lubricate and install o-ring seal into counterbore on top of manifold assembly. Install cap boss into manifold assembly bore. 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.

I1

I2

I3

I4

I5

I6

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. flange to manifold with cap screws. J1 Attach 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.)

For additional technical assistance, call: P.O. Box 9070, Fort Wayne, IN 46899

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1-800-624-8511