REBUILD PROCEDURES: SERIES BCZUS UNIVERSAL NOZZLE CYLINDER DISASSEMBLY OF CYLINDER REBUILD / REASSEMBLY

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1 PHD, Inc. makes no warranty as to the fitness of its products or as to the length of service life after being repaired or parts replaced by anyone other than authorized employees of PHD, Inc. In no event shall PHD, Inc. be liable for loss of profits, indirect, consequential, or incidental damages arising out of the use of PHD Products. DISASSEMBLY OF CYLINDER 1) WARNING: All air pressure in unit must be exhausted prior to disassembly of nozzle cylinder. 2) Remove nut from end of piston rod. 3) Remove compression seal from end of cap. 4) Remove fasteners and safety washer from cap. 5) Slide cap from piston and body. 6) Remove retaining ring, tube spacer and diffuser from inside cap. 7) Remove o-ring and shock pad from cap. 8) Slide piston from body. 9) If detent rings and detent o-ring are present, remove from piston. 10) Remove cap rod seals and cap wear rings from inside of piston. NOTE: Rod seals are comprised of two parts, an o-ring and a seal ring, both must be removed. 11) Remove piston rod seal and piston wear ring from body. NOTE: Piston seals are comprised of two parts, an o-ring and a seal ring, both must be removed. 12) Press wiper retainer from body and remove wiper. NOTE: Exercise caution to prevent damage to wiper retainer. 13) Remove manifold and valve from body. 14) Clean and inspect all components. Excessively worn or damaged components should be replaced. SEAL ROD SEAL WEAR RING ROD SEAL BODY WEAR RING COMPRESSION SEAL WEAR RING STATIC O-RING WIPER RETAINER DIFFUSER 2X FASTENER 2X SAFETY WASHER NUT ROD SEAL WIPER (Includes o-ring and wiper ring) REBUILD / REASSEMBLY 1) PHD recommends using Loctite 242 thread locker on all threaded fasteners. 2) Static seals may be lubricated for assembly purposes using lubrication per FDA Regulation 21CFR ) Be careful to prevent cutting or damaging seals during reassembly. RETAINING RING TUBE SPACER SHOCK PAD = LOCTITE 242 THREAD LOCKER = LUBRICANT PER FDA REGULATION 21CFR TOOLS NEEDED: - PHD BCZUS tooling kit # Open end wrench: 5/8" or 16mm and 7/16" - Hex wrenches: M4 and M5 - Small flat blade screwdriver in-lb torque wrench with M4 and M5 hex attachments 1

2 SHOCK PAD ASSEMBLY A1) Slip shock pad over rod on cap. A2) Using pusher tool #86284, push shock pad all the way down cap rod until it snaps into groove at cap retract face. A3) Install cap o-ring into groove on cap. (Sparingly coat o-ring with lubricant per FDA Regulation 21CFR ) SHOCK PAD SHOCK PAD O-RING O-RING SHOCK PAD SHOCK PAD SIZER/INSTALL SIZER/INSTALL TOOL PER TOOL PER = LUBRICANT = PER LUBRICANT FDA PER FDA REGULATION REGULATION 21CFR CFR GROOVE GROOVE RETRACT FACE RETRACT FACE STATIC O-RING STATIC O-RING SPARINGLY SPARINGLY BODY ASSEMBLY B1) Install piston wear ring into groove. B2) Install wiper seal into groove. B3) Press wiper retainer into counterbore in end of body. B4) Install o-ring part of piston rod seal into groove. B5) Shape seal ring part of piston rod seal as shown in Figure 1. Install into groove over o-ring. Note: Once seal ring is formed it must be inserted! into groove as soon as possible so it does not retain installation shape. B6) Once everything is installed into body, insert sizer/install tool into ID of wiper, wear ring and seal. WIPER RETAINER WIPER RETAINER (Includes o-ring (Includes and wiper o-ring ring) and wiper ring) ROD SEAL ROD SEAL (Includes o-ring (Includes and seal o-ring ring) and seal ring) WEAR RING WEAR RING BODY BODY SIZER/INSTALL SIZER/INSTALL TOOL TOOL BODY PER PER BODY WIPER WIPER WIPER RETAINER WIPER RETAINER ROD SEAL ROD SEAL R R FIGURE FIGURE 1 1 WIPER Installation shape Installation shape WIPER WEAR RING WEAR RING DETAIL DETAIL R R 2

3 C1) Install o-ring part of cap rod seal into groove. C2) Shape seal ring part of piston rod seal and install into tool # C3) Slip tool #86905 into end of piston rod until seated. C4) Insert pusher tool #86906 into tool #86905 until seated and remove both tools. C5) Reach into piston rod ID and reshape seal ring round to better! seat into groove. Note: Once seal ring is formed it must be inserted into groove as soon as possible so it does not retain installation shape. ROD SEAL ROD SEAL PUSHER TOOL PER ROD SEAL HOLDER TOOL PER ROD SEAL O-RING ROD INSTALL RING AS SHOWN IN END OF TOOL ROD SEAL RING C6) Install o-ring part of cap rod seal into groove. C7) Shape seal ring part of piston rod seal and install into tool # C8) Slip tool #86956 onto tool # C9) Slip tool #86956 and tool #86905 into end of piston rod until seated. C10) Insert pusher tool #86906 into tool #86905 until seated and remove both tools. C11) Reach into piston rod ID and reshape seal ring round to better seat into groove. Note: Once seal ring is formed it must be inserted! into groove as soon as possible so it does not retain installation shape. ROD SEAL ROD SEAL PUSHER TOOL PER ROD SEAL HOLDER TOOL PER ROD SEAL SPACER TOOL PER ROD SEAL O-RING ROD INSTALL RING AS SHOWN IN END OF TOOL ROD SEAL RING 3

4 C12) Curl cap wear ring similar to Figure 2. C13) Slide cap wear ring into piston and seat into groove - both ends. C14) Install rod sizing tool #86285 into end of piston so that all seals and wear rings are supported. WEAR RING WEAR RING 40mm ROD SIZING TOOL PER FIGURE 2 Installation shape C14) Install piston rod seal o-ring into groove. C15) Slip drift tool #86287 onto piston rod until it is seated against extend shoulder. C16) Slip piston rod seal ring onto tool #86287 until snug. C17) Slip tool #86286 onto end of piston rod. C18) Push tool #86286 into piston rod seal ring driving up tool #86287 until piston rod seal ring snaps into groove, then remove both tools. Note: Once seal ring is formed it must be inserted into groove as soon as possible so it does! not retain installation shape. SEAL ROD SIZING TOOL PER SEAL PUSHER TOOL PER ROD SEAL RING ROD SEAL O-RING EXTEND SHOULDER SEAL DRIFT TOOL PER ROD 4

5 C19) Install piston assembly into piston sizing tool #86288 and to bottom of tool. C20) Let assembly sit for couple of minutes to allow piston seals to reshape to their pre-installation form. SEAL SIZING TOOL PER ROD SIZING TOOL PER ROD ASSEMBLY -H55 OPTION C21) Install detent o-ring on piston assembly in groove shown (See Figure 3). C22) Just before installing piston assembly into bore, place both detent rings into groove in piston as shown (See Figure 3). DETAIL FIGURE 3 2X DETENT RING DETENT O-RING INSTALL DETENT RING IN DIRECTION SHOWN ROD SIZING TOOL PER ROD ASSEMBLY FIGURE 3 5

6 / BODY ASSEMBLY D1) Once piston seal sizing is complete, remove piston rod assembly from sizing tool. D2) Align tool #86289 to bore in body. D3) Slip piston rod assembly into tool #86289 and into body bore. D4) As piston rod assembly is pushing into bore, it will in turn push sizer/install tool #86284 out of body. BODY ASSEMBLY SLEEVE TOOL PER SIZER/INSTALL TOOL PER ROD ASSEMBLY E1) Slide diffuser into counterbore in end of cap. E2) Slide tube spacer into counterbore in cap and seat against diffuser. E3) Install retaining ring into end of cap. DIFFUSER TUBE SPACER RETAINING RING RETAINING RING TUBE SPACER DIFFUSER 6

7 / BODY ASSEMBLY F1) Install cap assembly into body. This will push tool #86285 from end of piston. F2) Push cap into body bore until it seats at end of body. F3) Apply thread locker to fastener threads. F4) Secure cap to body using safety washers and fasteners and torque to Chart 1. M5 HEX WRENCH 2X TO BODY SHCS 2X SAFETY WASHER ASSEMBLY BODY ASSEMBLY ROD ASSEMBLY = LOCTITE 242 THREAD LOCKER ROD SIZING TOOL PER TORQUE CHART 1 PART DESCRIPTION TORQUE TO BODY SHCS 90 in-lb 10.2 Nm 7

8 -MC3 / -U22 OPTION ASSEMBLY G1) Install o-rings into counterbores on bottom of manifold assembly. G2) Apply thread locker to manifold SHCS threads. G3) Slip safety washers over manifold SHCS and through manifold assembly G4) Secure manifold assembly to body and torque to Chart 1. G5) Install orifice plug into valve exhaust port as shown. G6) Thread mufflers into valve exhaust ports. G7) Apply thread locker to valve SHCS threads. G8) Secure valve to manifold assembly and torque to Chart 1. G9) Install elbow fitting into valve incoming air port as shown. VALVE M4 HEX WRENCH 2X VALVE SHCS (PART OF VALVE) -CTX OPTION ASSEMBLY H1) Apply thread locker to target SHCS threads. H2) Slip safety washers over target SHCS and through target. H3) Secure target to body and torque to Chart 1. 5/8" or 16mm ELBOW FITTING 2X VALVE O-RINGS (PART OF VALVE) ORIFICE PLUG 7/16" 2X MUFFLER M4 HEX WRENCH 4X MANIFOLD SHCS 4X SAFETY WASHER 2X SAFETY WASHER TARGET MANIFOLD ASSEMBLY 2X O-RINGS M5 HEX WRENCH 2X TARGET SHCS = LOCTITE 242 THREAD LOCKER TORQUE CHART 1 PART DESCRIPTION TORQUE in-lb Nm VALVE SHCS MANIFOLD SHCS TARGET SHCS

9 SHCS INCLUDED WITH VALVE O-RINGS INCLUDED WITH VALVE 50 -CT1 & -CT2 OPTIONS -H55 OPTION MC3 OPTION = LOCTITE 242 THREAD LOCKER = LUBRICANT PER FDA REGULATION 21CFR U22 OPTION (INCLUDES -MC3 OPTION) 30 O-RINGS INCLUDED WITH MANIFOLD ASSEMBLY KIT DESCRIPTION KIT NUMBER COLOR CODE Repair Kit Full unit description required followed by -H9010 Detent Kit Manifold Kit Orifice Kit CT1 Target Kit CT2 Target Kit

10 CYLINDER ONLY PARTS LIST 1 Body Cap Piston Shock Pad Diffuser Spacer Tube Retaining Ring Full unit description required followed by -H Compression Seal Sold as part of Repair Kit (-H9010*) 9 70mm Piston Seal Sold as part of Repair Kit (-H9010*) 10 56mm Rod Seal Sold as part of Repair Kit (-H9010*) 11 40mm Rod Seal Sold as part of Repair Kit (-H9010*) 12 O-Ring Seal Sold as part of Repair Kit (-H9010*) 13 56mm Wear Ring Sold as part of Repair Kit (-H9010*) 14 40mm Wear Ring Sold as part of Repair Kit (-H9010*) 15 Fastener Serrated Safety Washer mm Rod Scraper Sold as part of Repair Kit (-H9010*) 18 Rod Scraper Retainer Locking Nut Full unit description required followed by -H2001 NOTE: *Full unit description required (followed by -Hxxxx) -MC3 OPTION PARTS LIST 30 Manifold Assembly Fastener Serrated Safety Washer U22 OPTION PARTS LIST 30 Manifold Assembly Fastener Serrated Safety Washer Orifice Plug Muffler Elbow Fitting Series Mac Valve CT1 OPTION PARTS LIST 50 Target Fastener Serrated Safety Washer CT2 OPTION PARTS LIST 50 Target Fastener Serrated Safety Washer H55 OPTION PARTS LIST 70 O-Ring Seal Detent Ring NOTE: *Full unit description required (followed by -Hxxxx) 10