SERIES1 NOZZLE CYLINDER REPAIR PROCEDURES

Transcription

1 THE FOLLOWING REPAIR PROCEDURE ENCOMPASSES THESE PHD ML UNITS : - ML309435, ML310142, ML310153, ML310254, ML310295, ML310427, 1) Refer to individual ML exploded view for actual part numbers. 2) Not all steps apply to all ML's listed, consult individual ML's for more information. FIGURE A 8X SHCS 2X CLAMP BAR UNIT TO MACHINE ASSEMBLY PROCEDURE: 1) All seals and wear surfaces must be lubricated with FDA approved Dow Corning White EP lubricant prior to assembly. Recommended lubricant is provided in repair kit. 2) PHD recommends using Loctite 242 thread locker for all threaded fasteners. 3) Press dowel pins into manifold mount and manifold base until seated. (Figure A) 4) Attach both clamp bars and manifold mount to stretch rod housing shafts and loosely fasten with 8 SHCS provided, using recommended thread locker at this time. (Figure A) 5) Align manifold base onto manifold mount using dowels as shown. (Figure A) 6) Using recommended thread locker, torque 4 cap screws to 200 in-lb [23 Nm]. (Figure A) 7) Install o-rings into 2 counterbores in manifold base. (Figure A) 8) Align nozzle cylinder onto manifold base using dowels as shown. (Figure B) 9) Using recommended thread locker, torque all 4 cap screws to 200 in-lb [23 Nm]. (Figure B) 10) Install o-rings into counterbore in side of nozzle cylinder. (Figure B) 11) Assembly is in place, torque 8 cap screws to 200 in-lb [23 Nm]. (Figure B) 12) Install o-rings into appropriate counterbores. (Figure C) 13) Attach mufflers to valve and hand tighten + 1/4 turn. (Figure C) 14) Mount valve manifold to manifold base. (Figure C) 15) Using recommended thread locker, torque 4 cap screws to 80 in-lb [9 Nm]. (Figure C) 16) Install valve onto valve manifold. (Figure C) 17) Using recommended thread locker, torque 2 cap screws to 20 in-lb [2.5 Nm]. (Figure C) 18) Install 1/4 BSPP port plugs in bottom of manifold base and hand tighten + 1/4 turn. (Figure C) 19) Install o-rings into appropriate counterbores. (Figure D) 20) Attach mufflers to valve and hand tighten + 1/4 turn. (Figure D) 21) Install valve onto bottom of manifold base. (Figure D) 22) Using recommended thread locker, torque 2 cap screws to 20 in-lb [2.5 Nm]. (Figure D) 23) Install 3/8 BSPP port plugs in side of manifold base and hand tighten + 1/4 turn. (Figure D) 2X FIGURE B FIGURE C 2X DOWEL PIN 2X DOWEL PIN NOZZLE CYLINDER 2X MANIFOLD 2X VALVE MANIFOLD MOUNT 8X SHCS KIT; NOZZLE MOUNTING, SERIES 1 PER VALVE MANIFOLD FIGURE D 2X MUFFLER 2X 1/4 BSPP PORT PLUG 2X MUFFLER VALVE KIT; SIDE MOUNT, WITH MAC 400 VALVE PER VALVE KIT; BOTTOM MOUNT, WITH MAC 400 VALVE PER X MANIFOLD 2X 3/8 BSPP PORT PLUG

2 DISASSEMBLY PROCEDURES 1) WARNING: All air pressure in unit must be exhausted prior to disassembly of nozzle cylinder. 2 During disassembly, be careful to avoid scratching or damaging sealing surfaces. A non-metallic screwdriver (75682) has been included with each repair kit to help prevent damage while removing seals. 3) Using 6mm hex wrench, remove all 4 LHCS from cap, and remove cap. (Figure 1) 4) Using 6mm hex wrench, remove all 4 SHCS from tube. Notice that tube screws are longer than cap screws. Remove retract spring from both sides of cylinder. (Figure 1) 5) Remove retaining ring from cap. (Figure 2) 6) Using small flat blade screwdriver (not included), pry rod wiper out of cap. (Figure 2) 7) Using small diameter of tool and arbor press, press bushing out of cap. (Figure 3) 8) Pry small rod seal from of cap using tool (Figure 4) 9) Using 4mm hex wrench, remove all 4 SHCS and washers from nozzle bell and nozzle bell. (Figure 5) 10) Remove o-ring seal from non-rotating plate. (Figure 6) 11) Using 6mm hex wrench, remove 2 SHCS and unscrew non-rotating plate from P & R. (Figure 7) 12) Pry o-ring from back of non-rotating plate using tool (Figure 8) 13) Remove shafts and nut from unit. (Figure 9) 14) Remove both retaining ring and bearings from body. (Figure 10) 15) Separate tube from body and remove piston rod from assembly. (Figure 11) 16) Carefully remove P & R from body. (Figure 12) *75511 is for 14 mm stretching cylinder. FIGURE 1 2X SPRING FIGURE 2 ROD WIPER FLAT TIP SCREW DRIVER (NOT INCLUDED) FIGURE 3 ARBOR 75511* FIGURE 4 FIGURE 5 FIGURE 6 NON-ROTATING PLATE FIGURE 7 FIGURE 8 NON-ROTATING PLATE DIFFUSER NOZZLE BELL GROOVE 4X WASHER 4X FHCS NON- ROTATING PLATE FIGURE 9 FIGURE 10 FIGURE 11 FIGURE 12 NUT 2X SHAFT 2X SHAFT 2X P & R ASSEMBLY 2

3 DISASSEMBLY PROCEDURES 17) Pry rod seal retainer from rod seal retainer using tool (Figure 13) 18) Remove preform nut from stop tube using spanner per PHD # ** (or equivalent). (Figure 14) 19) Pry preform seal from stop tube using tool (Figure 14)20) Remove o-ring seal from between non-guide preform and mounting ring. (Figure 14) 21) Remove wear ring, shock pads and pressure piston seals from piston rod. (Figure 15) 22) To remove high pressure piston seals, use tool to lift up under the seals and cut seals. 23) Remove retaining ring from body. (Figure 16) 24) Using small diameter of tool * and arbor press, press rod seal retainer out of body. (Figure 16) 25) Pry rod seal retainer o-ring from body using tool (Figure 17) 26) Repair kit provides new components for wear items to completely rebuild unit. Unless fastener kit was also purchased, keep all SHCS to repair unit. Discard all old soft parts and clean all remaining parts. FIGURE 13 FIGURE 15 EXTEND SHOCK PAD RETAINER MARK SIDE NON-GUIDE FIGURE 14 PREFORM STOP PREFORM RETRACT SHOCK PAD WEAR RING PREFORM NUT ** HIGH URE S DISCARD ALL OF THE PARTS LABELED **Spanner is for hook style (Ø68 - Ø75) Spanner is for 28 mm bell assembly. *Tool is for 14 mm stretching cylinder. FIGURE 16 ARBOR FIGURE 17 RETAINER * RETAINING RING ASSEMBLY PROCEDURES 1) All seals and wear surfaces must be lubricated with FDA approved Dow Corning White EP lubricant prior to assembly. Recommended lubricant is provided in repair kit. 2) PHD recommends using Loctite 242 thread locker for all threaded fasteners. 3) Place piston seals onto piston rod. (Figure 18, Detail R) 4) Press shock pads onto piston rod. (Figure 18, Detail R) 5) Place 75565* mandrel onto end of piston rod. Place piston seal with lip orientation shown in Figure 18, Detail S on 75565* mandrel. Using tool and arbor press, provide constant force of approximately 120 lb [534 N]. Seal should slide down tool and into second piston seal groove. Warning: Do not use impact force such as hammer to install piston seal. 6) Place high pressure piston seal on piston rod with lip orientation as shown. (Figure 18) 7) Using large diameter of tool * and arbor press, press bushing with chamfered side down into body until seated by tool depth. (Figure 19) 8) Install o-ring seal into body. (Figure 20) 9) Install rod seal into rod seal retainer then into body, install retaining ring into body. (Figure 20) FIGURE 18 S R 120 lb [534 N] PUSHER LOW URE 75565* MANDREL PISTON PISTON ROD Detail S HIGH URE RETRACT SHOCK PAD **Spanner is for hook style (Ø68 - Ø75) Spanner is for 28 mm bell assembly. EXTEND SHOCK PAD Detail R FIGURE 19 FIGURE * FLANGE INSTALL ROD AS SHOWN RETAINER MARK *Tool is for 14 mm stretching cylinder. *Tool is for 14 mm stretch rod. 3

4 ASSEMBLY PROCEDURES 10) Slip P & R into body by slightly compressing from lip seal. (Figure 21) 11) Wrap wear ring piston rod and while holding wear ring ends, slip tube over P & R. (Figure 22) 12) Place o-ring onto tube and lubricate tube bore. (Figure 22) 13) Work tube over high pressure seals and seat tube fully against body aligning all flat sides. (Figure 22) 14) Using recommended thread locker, torque tube screws to 200 in-lb [23 Nm]. (Figure 1) 15) Install o-ring into non-rotating plate (Figure 23) 16) Insert shaft bushings into body and secure with retaining ring by separating coils and working retaining ring in circle around groove (Figure 23) 17) Slip shafts into shaft bushings (Figure 23) 18) Screw nut to piston rod (Figure 23) 19) Screw non-rotating plate onto piston rod until seated, screw nut against non-rotating plate and torque to 250 in-lbs (figure 23) 20) Align non-rotating plate to insert shafts into counterbores, secure with SHCS, torque to 140 in-lbs (Figure 23) 21) Using large diameter of tool 75511* and arbor press, install cap bushing until seated by tool depth. (Figure 30) 22) Install rod seal into cap with orientation as shown. (Figure 31) 23) Place o-ring onto cap. (Figure 31) 24) Using tool * and arbor press, press rod wiper into cap until fully seated. (Figure 32) 25) Install retaining ring by separating coils and working retaining ring in a circle around groove. (Figure 13) 26) Work cap assembly onto tube until fully seated. (Figure 1) 27) Using recommended thread locker, torque cap screws to 200 in-lb [23 Nm]. (Figure 1) 28) Place non-preform guide o-ring between tube and non-preform guide. (Figure 33 & 20) 29) Place preform seal on end of tube, thread nut onto tube. (Figure 33 & 20) 30) Using recommended thread locker and tools, torque nut to 200 in-lb [23 Nm]. (Figure 33 & 20) 31) Attach bell assembly to non-rotating plate using 4 washers and 4 SHCS. (Figure 3) 32) Using recommended thread locker, torque SHCS to 80 in-lb [9 Nm]. (Figure 3) 33) Install springs onto spring pins. (Figure 2) FIGURE 21 FIGURE 22 SLIP OVER P & R FIGURE 23 NUT NON-ROTATING PLATE SHCS SLIP P&R INTO WEAR RING SHAFT SHAFT FIGURE * FLANGE FIGURE 31 FIGURE * ROD WIPER FIGURE 33 PREFORM NUT NON-PREFORM GUIDE NON-PREFORM GUIDE PREFORM *Tool is for 14 mm stretching cylinder. 4

5 TO WIPER 2X EXTENSION SPRING HOOK ENDS BORE ID HIGH URE BORE ID TO WEAR RING RETRACT SHOCK PAD PISTON & ROD PISTON & ROD RETAINER NUT DIFFUSER 2X SHAFT 2X EXTEND SHOCK PAD 4X RETURN SPRING PIN 2X SHAFT NON-ROTATING PLATE TO SHAFT ASSEMBLY PROCEDURE 1) All seals and wear surfaces must be lubricated with FDA approved. Dow Corning White EP lubricant prior to assembly. Recommended lubricant is provided in repair kit. 2) PHD recommends using Loctite 242 thread locker for all threaded fasteners. = THREAD LOCKER = FOOD GRADE LUBRICANT 5