Phoenix SystemsPHOENIX 5000 REPAIR GUIDE

Although the schematic for the Phoenix 5000 Gun lists 40 separate items that make up the entire assembly, the majority of those parts will never, or at the very least rarely, need to be replaced.

There are (2) rebuild categories that will be discussed. They are the “Minor” and “Major” rebuilds. The “Minor” rebuild is the most common while the “Major” rebuild is reserved for repairs that are necessary due to the failure of the air side of the gun.

***NOTE*** When any O-Rings are being replaced, be sure to use an adequate amount of silicon lubricant to prevent any damage to the O-Rings.

“MINOR” REBUILD:

DRAIN ALL THE FLUID FROM THE HOSES AND DISCONNECT THE AIR BEFORE CONTINUING.

Remove the Yoke (#8) by removing the Retaining Pin (#11) and the Retaining Plate (#10), and then pulling the Cover Plate (#9)/Yoke (#8) Assembly from the right side of the gun. In some instances, it might be necessary to remove the Air Assist Valve (#15) for clearance.

Remove the two Fluid Plugs (#14) with an ¼” Allen Wrench.

Remove the two Fluid Needles (#12) by pushing them into the opening at the center of the gun using a punch-like object between 1/8” and 3/16”.

***NOTE*** If the Fluid Needles are stuck because of gelling, lightly tap the end of the punch with a hammer. But, be careful not to cause damage to the needles. If this does not work, heat must be applied.

Once the needles are removed, the O-Ring Seals and Spacers (#13) can be removed from the front of the gun using a small pick. Be careful not to damage the inside of the Ports’ Walls.

Clean the Fluid Ports with an acetone soaked rag or brush and flush to ensure there is no debris in the openings.

Once the ports are clean, replace the O-Ring Seals and the Spacers using the following method. Place the bottom O-Ring in first using a 9/32” Punch. Ensure that the O-Ring is flat against the bottom of the Port, then, place the Stainless Spacer against the O-Ring. Next place the Teflon Seat against the Spacer using the same punch to ensure it is firmly seated and then the next spacer. Place the last O-Ring in the port and screw in the Fluid Plugs (#14). DO NOT TIGHTEN THE PLUGS AT THIS TIME.

Insert the Fluid Needles (#12) into the opening at the center of the gun using a pair of needle-nose pliers. Push them through the rear O-Rings and into the port. NOTE: Adding a small amount of silicon lubricant will help this process.

At this point, you will need to tighten the Fluid Plugs (#14). Using the same pliers you used in inserting the needles, slide the needles back and forth while tightening the Fluid Plugs with the ¼” allen wrench. The proper adjustment will be achieved when moderate resistance is felt on the needles.

CAUTION: DO NOT OVERTIGHTEN THE FLUID

PLUGS. OVERTIGHTENING THE FLUID PLUGS WHICH WILL CAUSE SHORT SEAL LIFE AND POSSIBLE DAMAGE TO THE SPACERS.

Once the needle tension is adjusted, replace the Yoke (#8). Push the Yoke/Cover Plate Assembly into the opening ensuring that the slot on the yoke is aligned with the notches in the needles (#12) and the Air Piston (#6). NOTE: You may have to manually push the needles further into their respective ports. Use the Yoke to accomplish this in order to keep from pushing them in too far. Once the yoke is pushed through, place the Retaining Plate (#10) and the Retaining Pin (#11) into their appropriate positions.

Congratulations! You have just completed a “MINOR” Rebuild.To Begin using your system once again, please refer to the “Initial” & “Daily” Start-Up Guides or continue on with this guide to perform a “MAJOR” Rebuild.

“MAJOR” REBUILD:

The Major Rebuild consists of the “Fluid” Side of the gun and the “Air” Side of the Gun. The “Fluid” Side of the Gun is covered in the Minor Rebuild Section and will not be repeated here except for references where the two overlap.

Perform a complete Unit SHUT-DOWN as described in your SHUT-DOWN MANUAL – WEEKEND/HOLIDAY. DO Not attempt to continue with this guide until the SHUT-DOWN is completed properly.

Remove the hoses that are attached to the back of your gun. Use care to make certain that there is NO fluid or air pressure in the lines before disconnecting them. Also, as you remove the hoses from the back of the gun, it is a wise choice to use a simple piece of tape to mask off the ends of the hoses so you do not get shop dust or dirt in the lines which could potentially clog or damage your unit.

Take your gun to a clean workbench or suitable surface where you are not in danger of losing parts as you disassemble your gun. Begin by cleaning off the outside surfaces of your gun with either a paintbrush or rag with some solvent. It is OK to completely submerge your gun in solvent as no damage will occur.

First remove the hose fittings from the rear of the Gun. Be sure to notice the two Check Balls & Springs on the catalyst side of the gun. Do not drop them as damage will occur that will cause them not to perform as engineered. If you should happen to drop the Ball on the floor or on your workbench, REPLACE IT.

***NOTE*** There is no reason to remove the Cover Plate (#5) in any of the operations.

Remove the Yoke (#8) by removing the Retaining Pin (#11) and the Retaining Plate (#10). Pull the Cover Plate (#9)/Yoke (#8) Assembly from the right side of the gun. In some instances, it might be necessary to remove the Air Assist Valve (#15) for clearance.

Unscrew the Set Screw (#24) and remove the Air Cylinder Plug (#7) using a 1/4-20 Bolt.

Next remove the Air Piston (#6) by pushing on the stem protruding into the center opening of the gun.

NOTE: DO NOT USE VASELINE OR ANY PETROLEUM PRODUCT ON THE SEALS OR CYLINDER WALL. THE SEALS WILL SWELL AND FAIL PREMATURELY.

Replace the O-Rings (#30, #38), clean the air cylinder of any debris or residue, add a small amount of silicon lube to the cylinder surface and seals and replace the components. The easiest way to install the Air Piston (#6) is to place it on your workbench and drop the gun body onto it. This prevents any cocking of the Piston.

Install the Air Cylinder Plug (#7) and the Set Screw (#24). Be sure to notice the orientation of the receiving hole for the set screw on the Plug (#7)

You can now reattach your hoses to the back of the gun or continue on to the next section.NOTE: When reinstalling the Hose Fittings. DO NOT OVERTIGHTEN as it will deform the gun body causing the Air Cylinder Plug to be difficult to install or remove

Congratulations! You have just completed a “MAJOR - UPPER” Rebuild. To Begin using your system once again, please refer to the “Initial” & “Daily” Start-Up Guides or continue on with this guide to perform a “MAJOR - LOWER” Rebuild.

“MAJOR” REBUILD (LOWER GUN SECTION):

It is probable that during the life of your gun, the O-Rings (#38) on the Air Valve Piston (#19) will wear to a point that they no longer hold air and cease to operate the Air Piston (#6). When this occurs, it will be necessary to replace these O-Rings.

Remove the (2) Handle Bolts Screws (#23) and pull downward on the handle to remove it.

Begin this operation by pushing out the (2) Retaining Pins (#29) and removing the Trigger Assembly(#17, #18).

Remove the Air Valve Piston (#19) and replace the (4) O-Rings (#38).

Using an air hose, blow out the passageways and check to make sure they are clear. If they are not, it might become necessary to remove the Air Valve Cylinder (#20) and clear these passageways. If you need to remove the Air Valve Cylinder (#20), use a right angle pick and place the pick end into one of the (3) ports of the cylinder. Pull the cylinder out with a single continuous motion but be careful not to scratch the inside surface of the cylinder as this will reduce the life of the (4) O-Rings (#38). When you have extracted the Air Valve Cylinder, replce the (4) O-Rings that are on it (#36). Lubricate the O-Rings on the Air Valve Piston (#19) and the Air Valve Cylinder (#20) and replace them into the handle. Replace the Trigger Assembly(#17, #18) and the Retaining Pins (#29).

You are now ready to reattach the handle to the gun. Place the gun body upside down on your workbench. Push the handle onto the long Set Screws (#28) and while pushing firmly in a downward motion, tighten the two Set Screws (#23). Do not overtighten these Set Screws as the handle is plastic and they can strip out of the holes. Check to see if the handle has been drawn all the way to the gun body. If not, redo this operation.

Reattach the hoses to the handle of your gun.NOTE: When reinstalling the Hose Fittings. DO NOT OVERTIGHTEN as it will deform the gun body causing the Air Cylinder Plug to be difficult to install or remove

Congratulations! You have just completed a “MAJOR - LOWER” Rebuild. To Begin using your system once again, please refer to the “Initial” & “Daily” Start-Up Guides.