STRAIGHT FITTING ORIFICE DISK MUFFLER MANIFOLD MOUNTING PLATE MULTI-FUNCTION IMPACT SEAL CYLINDER TUBE 1/4 BSPP ELBOW FITTING HEAD ASSEMBLY

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1 Disassembly OF THE CYLINDER 1) 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. ) Remove flange and jam nut. 6) Remove polyurethane tubes. 7) Remove fittings from head and cap. ) 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. FLANGE 4X FLANGE TO SHCS JAM NUT I.D. ROD BUSHING REBUILD/Reassembly OF THE CYLINDER rebuild procedures: SERIES BCK1 CYLINDERS MUFFLER 4X MOUNT PLT TO / SHCS 4X SAFETY WASHER 4X WASHER 1) 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 lubricant for lubrication of air cylinders during reassembly. SEE START-UP AND INFORMATION SHEET FOR CYLINDER INSTALLATION AND ALIGNMENT PROCEDURES. MANIFOLD MOUNTING PLATE CYLINDER TUBE ASSEMBLY STRAIGHT FITTING ORIFICE DISK KIT DESCRIPTION KIT NUMBER COLOR CODE Seal Kit* -H9000* Repair Kit* -H9010* Rod Eye Mounting Kit NOTE: *Full unit description required (followed by -Hxxxx) 2X MANIFOLD TO MOUNT PLT SHCS 2X SAFTEY WASHER 2X WASHER 3/ NPT RETRACT CUSHION O-RING POLYURETHANE TUBING ROD BEARING ROD BEARING BORE SHOULDER ASSEMBLY PISTON & ROD ASSEMBLY FIGURE 2 SNOUT RETAINING RING ORIENTATION FLANGE WEAR RING ASSEMBLY 1) 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. FIGURE 3 TOOLS NEEDED: - Hex wrenches: M4, M, M6, and M - 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 in-lb torque wrench with M4, M, M6 and M hex attachments 1 ROD BUSHING I.D.

2 rebuild procedures: SERIES BCK1 CYLINDERS ASSEMBLY 1) 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 multiimpact seal is critical for cushions to properly function. Caution: Over lubrication may cause the cushion to malfunction. FACE RETRACT COUNTERBORE FIGURE 4 CUSHION O-RING (10 ) (10 ) FIGURE! TAMPER EVIDENT TAG (SEE NOTE 2) 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. TO TUBE ASSEMBLY 1) 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. CHART 1 Shoulder Bolt w/ Female Thread 20 [2.2] M HEX WRENCH CYLINDER TUBE CYLINDER TUBE I.D. O.D. 2

3 rebuild procedures: SERIES BCK1 CYLINDERS PISTON ROD ASSEMBLY AND INSTALLATION INTO TUBE 1) 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. WEAR RING PISTON & ROD ASSEMBLY LARGEST GROOVE EVENLY DISTRIBUTE LUBE CYLINDER TUBE CYLINDER TUBE I.D. WEAR RING PISTON & ROD ASSEMBLY WITH WEAR RING AND SEALS INSTALLED ASSEMBLY TO TUBE 1) 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. CHART 1 Shoulder Bolt w/ Female Thread 20 [2.2] M HEX WRENCH ASSEMBLY CYLINDER TUBE ROD END 3

4 rebuild procedures: SERIES BCK1 CYLINDERS MOUNTING PLATE TO / 1) 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. M4 HEX WRENCH 4X PLATE FASTENER 4X SAFTEY WASHER 4X WASHER CHART 1 Valve Manifold Fastener (M) 120 [13.6] Plate Fastener (M4) 0 [9.2] Flange Mounting Fasteners 200 [22.6] SLOTS MOUNTING PLATE THREADED HOLES MANIFOLD TO MOUNTING PLATE 1) 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. ) Torque manifold to mount plate SHCS to Chart 1. M HEX WRENCH 2X VALVE MANIFOLD FASTENER 2X SAFTEY WASHER 2X WASHER FLANGE TO 1) 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. MOUNTING PLATE CYLINDER M6 HEX WRENCH 4X FLANGE MOUNT FASTENER FLANGE 4

5 rebuild procedures: SERIES BCK2 CYLINDERS LOCKING CYLINDER DISASSEMBLY A1) 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. A) Remove bushing from cap. A6) Remove rod bushing and plug from locking cylinder. CAUTION: Take care when removing the plug, it is under spring pressure A7) Remove spring and stop tube from body. A) 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. 4X CYLINDER TO SHCS 4X MOUNT PLT TO / SHCS 4X SAFTEY WASHER 4X WASHER BUSHING O-RING SEAL BUSHING LOCKING CYLINDER ASSEMBLY RETRACT LOCKING CYLINDER PLUG BUSHING TO BODY O-RING SEAL SPRING STOP TUBE BREATHER VENT BODY ASSEMBLY BODY ID CAUTION: UNDER SPRING PRESSURE NUT CUSHION O-RING WEAR RING FHCS P & R ASSEMBLY PISTON ROD BUSHING TO BODY O-RING SEAL ROD BUSHING PISTON & ROD ASSEMBLY REBUILD/Reassembly OF THE CYLINDER 1) 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 lubricant for lubrication of air cylinders during reassembly. TOOLS NEEDED: - Hex wrenches: M4, M, M6, and M - 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 in-lb torque wrench with M4, M, M6 and M hex attachments

6 rebuild procedures: SERIES BCK2 CYLINDERS LOCKING CYLINDER ASSEMBLY B1) 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. B) 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. BUSHING O-RING SEAL BUSHING LOCKING CYLINDER FACE COUNTERBORE RETRACT CUSHION O-RING FIGURE 4 TAMPER EVIDENT TAG (SEE NOTE 2) FIGURE 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 could void the warranty of the BCK cylinder. 6

7 rebuild procedures: SERIES BCK2 CYLINDERS LOCKING CYLINDER ASSEMBLY C1) 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). C) 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. C) 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. 4X SHCS M4 HEX WRENCH LOCKING CYLINDER ASSEMBLY ASSEMBLY FIGURE 7 BODY ASSEMBLY CAUTION: UNDER SPRING PRESSURE PLUG FHCS M4 HEX WRENCH P & R ASSEMBLY PISTON BUSHING TO BODY O-RING SEAL SPRING ROD STOP TUBE ID BODY BREATHER VENT CAUTION: SPRING MUST BE INSTALLED WITH TAPER OF SPRING AS SHOWN BUSHING TO BODY O-RING SEAL ROD BUSHING CHART 1 FHCS for P&R Assembly 0 [9.0] SHCS for locking Cylinder to Cap 40 [4.] FIGURE 6 7

8 rebuild procedures: SERIES BCK1 & 2 CYLINDERS FINAL ASSEMBLY AND OPTIONAL ASSEMBLY 1) Install orifice disk into manifold port, seat to bottom of threads. 2) Thread in mufflers into manifold ports 3 and. 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/ NPT elbow fittings into manifold In ports 2 and 4. ) Install elbow fittings into head and cap in cylinder. 6) Attach polyurethane tubing, running from the fitting to the 3/ NPT fitting. 7) Attach jam nut to rod end thread. ) 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. SOLENOID FASTENERS M2. HEX WRENCH VALVE FASTENERS M HEX WRENCH WHEN ATTACHING THE -U23 OPTION TO THE CYLINDER MANIFOLD, THE TWO M3 SHCS THAT HOLD THE SMALL MANIFOLD BLOCK TO THE VALVE BODY MUST BE REMOVED IN ORDER TO PROPERLY THE M6 SHCS THAT IS UNDER THE SMALL MANIFOLD. IF THE M6 SHCS IS NOT PROPERLY D, THE VALVE MAY LEAK AND THE M6 SHCS WILL DAMAGE BOTH THE SMALL MANIFOLD AND VALVE BODY. SMALL MANIFOLD BLOCK SEE START-UP AND INFORMATION SHEET FOR CYLINDER INSTALLATION AND ALIGNMENT PROCEDURES. Ø 16 mm STRAIGHTS FITTING -L2116 FITTING OPTION -U23 OPTIONAL VALVE -U19 OPTIONAL VALVE FITTING ADAPTOR MUFFLER 11/16" OPEN END WRENCH ORIFICE DISK M HEX WRENCH VALVE FASTENERS ROD END THREAD JAM NUT STRAIGHT FITTING 19mm OPEN END WRENCH MANIFOLD POLYURETHANE TUBING 3/ NPT 1mm OPEN END WRENCH 16mm OPEN END WRENCH POLYURETHANE TUBING CHART 1 Muffler 227 [2.6] Straight Fitting 227 [2.6] Elbow Fitting - Head/Cap 90 [10.2] Elbow Fitting - Manifold 227 [2.6] Valve Fastener (M) 140 [1.] Fitting Adaptor 227 [2.6] Solenoid Fasteners 20 [2.3] Fitting Adaptor 227 [2.6] - R13 OPTIONAL ROD EYE (HAND TIGHTEN) SECURE WITH LOCK NUT AFTER MACHINE INSTALLATION AND ADJUSTMENT. 16mm OPEN END WRENCH

9 rebuild procedures: SERIES BCK CYLINDERS KEY BCK1 & BCK2 Finished Tube Head Assembly Head Rod Bushing Rod Seal Retaining Ring Cap Assembly Cap Bushing Rod Seal O-Ring Seal Piston & Rod Assembly Piston Seal Wear Ring Multi-function Impact Seal Custom Shoulder Bolt Cushion O-Ring Seal Cap Shock Pad Jam Nut Socket Head Cap Screw Flange Elbow Fitting Finished Urethane Tubing 3/ NPT Elbow Fitting Metric Washer Serrated Safety Washer Socket Head Cap Screw Mounting Plate 3/ NPT ISO 2 Manifold 3/ NPT Muffler 3/ NPT Straight Fitting Port Orifice Metric Washer Serrated Safety Washer Socket Head Cap Screw Fitting Adaptor 16 mm Tube Fitting Full unit description followed by -H1300 Full unit description required followed by -H1100 Sold as part of Head Assembly Sold as part of Head Assembly, Sold as part of Repair Kit (-H9010*) Sold as part of Head Assembly, Sold as part of Seal Kit (-H9000*) and Repair Kit (-H9010*) Full unit description required followed by -H1200 Sold as part of Cap Assembly Sold as part of Cap Assembly, Seal kit (-H9004*) & Repair Kit (H9014*) Sold as part of Cap Assembly & Seal kit (-H9004*) Sold as part of Cap Assembly & Seal kit (-H9004*) Full unit description required followed by -H1000 Sold as part of Seal Kit (-H9000*) Sold as part of Repair Kit (-H9010*) Sold as part of Seal Kit (-H9000*) and Repair Kit (-H9010*) Sold as part of Seal Kit (-H9000*) and Repair Kit (-H9010*) 407 Full unit description required followed by -H Full unit description required followed by -H Full unit description required followed by -H Full unit description required followed by -H L2116 OPTION 1 0 SEE NOTE 2 2 M3 SHCS DETAIL K (10 ) (10 ) ALIGN IN WITH HOLE IN SEAL TO ALLOW FREE AIR FLOW THREAD TO BOTTOM OF MANIFOLD M6 SHCS SMALL MANIFOLD BLOCK -U23 OPTION A NOTE SEAL ORIENTATION AND LOCATION LOCATION 16 SEE DETAIL K SEE NOTE 1 TUBE BORE DETAIL R SEE DETAIL R 2B 2D A 14 2C F A U19 OPTION A 2B 2C 2D 3 3A 3D 3E 3F KEY BCK2 Locking Cylinder Assembly Piston & Rod Assembly Piston Rod Flat Head Cap Screw Body Assembly Body Exhaust Filter Bushing Plug Shock Pad Piston Seal Stop Tube Compression Spring O-Ring Seal Rod Seal Retaining Ring Socket Head Cap Screw Sold as part of Piston & Rod Assembly Sold as part of Piston & Rod Assembly Sold as part of Piston & Rod Assembly 07 Sold as part of Body Assembly Sold as part of Body Assembly Sold as part of Seal kit (-H9004*) & Repair Kit (H9014*) Sold as part of Seal kit (-H9004*) & Repair Kit (H9014*) Sold as part of Seal kit (-H9004*) & Repair Kit (H9014*) Sold as part of Seal kit (-H9004*) & Repair Kit (H9014*) Sold as part of Repair Kit (H9014*) BCK1 3E 3D 10 BCK1 & BCK2 KIT DESCRIPTION KIT NUMBER COLOR CODE Seal Kit* (Main Cylinder Only) -H9000* Repair Kit* (Main Cylinder Only) -H9010* Rod Eye Mounting Kit BCK2 KIT DESCRIPTION KIT NUMBER Seal Kit* (Retract Lock Cylinder Only) -H9004* COLOR CODE 4 Repair Kit* (Retract Lock Cylinder Only) -H9014* NOTE: *Full unit description required (followed by -Hxxxx)! NOTES: 1) 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 cylinder. 2) CAUTION: When attaching the -U23 option to the cylinder manifold (21), the two M6 SHCS that hold the pilot block to the valve body must be removed in order to properly attach the valve to the manifold. If the M6 SHCS are not properly torqued, the valve may leak and the SHCS will damage both the pilot block and the valve body. BCK L 40 40D CAUTION: UNDER SPRING PRESSURE 40J 40H 40G 40B 6 40BA 40B 40AA 40AB 40J 40F 40AC 40A 40E 40K 40C 40L 40 40A 40AA 40AB 40AC 40B 40BA 40BB 40C 40D 40E 40F 40G 40H 40J 40K 40L 41 KEY OPTION PART NUMBER 2 -U19 (ISO 2 Valve, Connector out Top) U23 (ISO 2 Valve, Connector out Side) R13 (See Rodeye Kit Number) 0 FIitting Adaptor mm Tube Fitting ! 9