MEDIUM DUTY CYLINDERS REPAIR MANUAL - PHD, Inclitstore.phdinc.com/pdf.asp?filename=MDCREPAIR.pdf · PHD, Inc. has a policy of continuous product improvement. PHD, Inc. reserves the

NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

Makers ofbrand Products

and®

®

®

MEDIUM DUTY CYLINDERS REPAIR MANUAL3/4, 1, 1-1/8, 1-3/8" BORE SERIES A, AV, HV

• PARTSLISTS• REPAIRKITS

CAT-MDCREPAIR

2

NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR

© Copyright 2012, by PHD, Inc. All Rights Reserved. Printed in the U.S.A.

PAGEMODEL NOMENCLATURE ........................................................................................................................ 3

PARTS LISTS AND REPAIR KITS

Exploded Views of 3/4, 1, 1-1/8" Bore ................................................................................................................................4 Parts List 3/4, 1, 1-1/8" Bore .............................................................................................................................................5 Exploded View of 1-3/8" Bore ............................................................................................................................................6 Parts List 1-3/8" Bore .........................................................................................................................................................7

TROUBLESHOOTING CHART ................................................................................................................... 8

REPAIR/REBUILDING Series A; 3/4, 1, 1-1/8" Bore Cylinders ............................................................................................................................ 9-10

Series AV; 3/4, 1, 1-1/8" Bore Cylinders ............................................................................................................................11

Series HV; 3/4, 1, 1-1/8" Bore Cylinders ...........................................................................................................................12 Series AV & HV; 1-3/8" Bore Cylinders ........................................................................................................................... 13-15

TORQUE SPECIFICATIONS - LUBRICATION ............................................................................................ 16

CONTENTS

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 re-placed by anyone other than authorized employees of PHD, Inc. In no event shall PHD, Inc. be liable for loss of profits, in direct, consequential, or incidental damages arising out of the use of PHD® and Tom Thumb® Products.

PHD, Inc. has a policy of continuous product improvement. PHD, Inc. reserves the right to change specifications and designs without notice.

LIMITATION OF WARRANTY

All PHD Products are guaranteed to be free of actual defects in material and workmanship, provided any such defect be reported to PHD in writing within 1 year of shipment from factory. This warranty is limited to replacing or repairing at the Company's option, F.O.B. the Company's factory, any part which, upon Company inspection, is found to have a defect in material and/or workmanship. The Company in no event shall be liable for indirect or consequential damages arising out of the use of PHD Products. Components purchased by the Company from others for inclusion by the Company shall be warranted to the extent set out above and/or to the guaranty or warranty, if any, made by the supplier of said component. APART FROM THE ABOVE EXPRESS WARRANTY, THERE ARE NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.PHD expressly reserves the right to substitute materials in the products described in the catalogs and any supplements thereto: however, this shall not apply to special order products and/or custom products where PHD is advised in writing of specific material requirements and agrees in writing to comply with the request for such specific materials.

3


MODEL NOMENCLATURE

PORT

CO

NTR

OL

BUIL

T-IN

MET

ERO

UT

FLO

WCO

NTR

OL

VALV

E

SCF

x-

1P

2AV

XI-

D3/

8 R

OD

G-M

-V

SER

IES

BOR

E

AV, H

V

3/4" 1"

1-1/

8"1-

3/8"

PRO

XIM

ITY

SWIT

CHM

OU

NTI

NG

BR

ACKE

TSSI

ZE N

O.

-31

-32

-33

-34

SER

IES

For u

se w

ith1-

3/8"

bor

e,Tr

unni

on

Mou

nt o

nly.

BOR

E SI

ZE

3/4"

BO

RE

1/4"

Sta

ndar

d R

od D

ia.

1/4-

28 T

hrea

d

1" B

OR

E5/

16" S

tand

ard

Rod

Dia

.5/

16-2

4 Th

read

1-1/

8" B

OR

E3/

8" S

tand

ard

Rod

Dia

.3/

8-24

Thr

ead

1-3/

8" B

OR

E1/

2" S

tand

ard

Rod

Dia

.3/

8-24

Thr

ead

AV HV A

- 150

psi

Air

- 150

0 ps

i Hyd

.- 1

50 p

si A

ir( 3

/4"-

1-1/

8")

CUSH

ION

OR

SH

OCK

PAD

OVE

RSI

ZE R

OD

To b

e sp

ecifi

ed o

nly

whe

nus

ing

a no

n-st

anda

rddi

amet

er. S

ee c

atal

og.

(Cus

hion

s, S

hock

Pad

s, a

ndSp

ring

Ret

urn

are

not a

vaila

ble

on th

e sa

me

end

of c

ylin

der.

Shoc

k Pa

ds a

nd 3

/4",

1", a

nd1-

1/8"

Cus

hion

s no

t ava

ilabl

eon

Ser

ies

HV.

)

DD

R DC B

BR BC

- Cus

hion

s on

bot

h en

ds- C

ushi

on o

n ro

d en

d- C

ushi

on o

n ca

p en

d- S

hock

Pad

s on

bot

h en

ds- S

hock

Pad

on

rod

end

- Sho

ck P

ad o

n ca

p en

d

P

PR PC

- Flo

w c

ontr

olbo

th e

nds

- Flo

w c

ontr

olon

hea

d en

d- F

low

con

trol

on c

ap e

nd

STAN

DAR

D S

TRO

KE L

ENG

THS

3/4"

BO

RE

1/4"

to 1

2"

1" B

OR

E1/

4" to

18"

1-1/

8" B

OR

E1/

4" to

18"

3/4"

, 1",

& 1

-1/8

" in

1/4"

in

crem

ents

1-3/

8" B

OR

E SI

ZE1/

2" to

24"

in 1

/2" i

ncre

men

ts

For L

onge

r Len

gths

, Co

nsul

t PH

D

SPR

ING

RET

UR

N

and/

orD

OU

BLE

RO

D E

ND

D -

Dou

ble

Rod

End

Cylin

ders

Leav

ebl

ank

ifno

tnee

ded.

SC SR- S

prin

g on

cap

end

- Spr

ing

on ro

d en

d( S

trok

e s a

vaila

ble

in

1/4"

incr

emen

ts u

p to

6")

A

- Str

oke

Adju

stm

ent,

1/2"

of a

djus

tmen

t sta

ndar

d (n

ot a

vail.

on

Serie

s H

V)

E

- Mag

netic

Pis

ton

for P

HD

Hal

l Effe

ct S

witc

hes

(not

ava

ilabl

e on

Ser

ies

A)

F - #

1 R

od E

nd, S

tand

ard

on 3

/4",

1", 1

-1/8

" Bor

e (S

ee N

ote

1)

G -

#2

Rod

End

, Sta

ndar

d on

1-3

/8" B

ore

(See

Not

e 1)

I

- #4

Rod

End

, Fem

ale

thre

ad o

n ro

d (S

ee N

ote

1) H

47 -

Rod

lok

(Rod

cla

mpi

ng d

evic

e in

stal

led.

Not

ava

ilabl

e w

ith Z

1 or

on

HV.

Se

e op

tion

page

.) (S

ee N

ote

3)

J - #

2X R

od E

nd, T

wic

e as

long

as

stan

dard

thre

ad (S

ee N

ote

1)

_K -

Ext

ra R

od E

xten

sion

, in

1/8"

incr

emen

ts (S

ee N

ote

2)

L - C

oars

e Th

read

Rod

End

(See

Not

e 1)

M

- M

agne

tic P

isto

n fo

r PH

D R

eed

Switc

hes

(not

app

licab

le o

n Se

ries

A)

N -

Pla

in R

od E

nd (S

ee N

ote

1)

Q -

Por

t in

Posi

tion

#1 (M

ust b

e sp

ecifi

ed if

requ

ired

with

mou

ntin

g st

yle

“F”

on 3

/4 to

1-1

/8 w

ith “

F” m

ount

ing

tab

on c

ap e

nd)

R

- P

orts

in P

ositi

on #

2

T - P

orts

in P

ositi

on #

3 (“

F” m

ount

ing

tab

on c

ap e

nd o

n 3/

4 to

1-1

/8

U -

Por

ts in

Pos

ition

#4

V

- Flu

oro-

Elas

tom

er S

eals

W

- C

lose

Tol

eran

ce S

trok

e, ±

.005

" str

oke

leng

th

Y

- SAE

Por

ts (H

V Se

ries

Onl

y) 3

/4, 1

, 1-1

/8" B

ore

Z1

- E

lect

role

ss N

icke

l Pla

te a

ll Fe

rrou

s Pa

rts

excl

udin

g R

od E

nds

OPT

ION

S

NO

TES:

1) F

or d

oubl

e ro

d cy

linde

rs, r

od e

nd o

ptio

ns w

ill b

e ap

plie

d to

bot

h en

ds o

f cy

linde

r.2)

For

dou

ble

rod

cylin

ders

, -_K

ext

ensi

on w

ill b

e ap

plie

d to

one

end

onl

y (h

ead

end/

prim

ary

mou

ntin

g en

d).

3) O

ptio

n pr

ovid

es a

dditi

onal

cyl

inde

r fle

xibi

lity,

but

may

alte

r the

dim

ensi

ons.

TO O

RD

ER S

PECI

FY:

Serie

s, M

ount

ing

Styl

e, B

ore

Size

, Str

oke,

Por

t Co

ntro

l, an

d an

y O

ptio

ns (i

f des

ired)

. Als

o sp

ecify

ro

d di

amet

er if

non

-sta

ndar

d. R

od c

oupl

ings

and

m

ount

ing

atta

chm

ents

mus

t be

orde

red

sepa

rate

ly.

- Fo

ot M

ount

, thr

u ho

le-

Botto

m M

ount

, Tap

ped

hole

s in

hea

d an

d ca

p-

Rod

Mou

nt, T

appe

d ho

les

on fr

ont f

ace

of h

ead

- Th

read

Mou

nt, T

hrea

ded

snou

t on

head

(shi

pped

with

mou

ntin

g nu

t)-

Rod

End

Fla

nge

- Ca

p En

d Fl

ange

- Cl

evis

Mou

nt, c

ap e

nd-

Pilo

t Mou

nt, T

hrea

ded

snou

t and

pilo

t dia

met

er

on h

ead

(shi

pped

with

mou

ntin

g nu

t)-

Pivo

t Mou

nt, P

ivot

on

cap

- Tr

unni

on M

ount

- Ti

erod

Mou

nt, T

iero

ds e

xten

d ou

t rod

end

- Ti

erod

Mou

nt, T

iero

ds e

xten

d ou

t cap

end

- Ti

erod

Mou

nt, T

iero

ds e

xten

d ou

t bot

h en

ds

*A

vaila

ble

on 3

/4",

1", a

nd 1

-1/8

" Bor

e on

ly *

*Ava

ilabl

e on

1-3

/8" B

ore

only

F B R T RF CF **K *L *P

**TR RR RC

RR

C

MO

UN

TIN

G S

TYLE

4


MEDIUM DUTY CYLINDERSSERIES A, AV, HV; 3/4, 1, 1-1/8" BORE

®

SERIES A, AV, HV MEDIUM DUTY CYLINDERS3/4, 1, 1-1/8" BORE EXPLODED VIEW

SERIES HV

SERIES A

SERIES AV

3

18

19

21

1

13

23

22

20

4

22

23

14

134

2

117

65

12

14

17

24

30

5

12

11

109

8

7

14

13

15

6

16

1614

CUSHION

SHOCK PAD

WITH -P HEAD

WITHOUT -P HEAD

SHOCK PAD

-A CAP

CUSHION

SPRING RETURN

5


PARTS LISTSERIES A, AV, HV; 3/4, 1, 1-1/8" BORE

SERIES A, AV, HV MEDIUM DUTY CYLINDERS3/4, 1, 1-1/8" BORE PARTS LIST AND REPAIR KITS

REPAIR KITSFull unit description required followed by -H9010NOTE: Repair kits include all seals and bushings.

SEAL KITSFull unit description required followed by -H9000NOTE: Seal kits include all seals and backup rings.

Full unit description required followed by -H1200Full unit description required followed by -H1300Full unit description required followed by -H1410Full unit description required followed by -H1000Full unit description required followed by -H1100

Sold as part ofRepair Kit only

Full unit description required followed by -H1700Full unit description required followed by -H1600

Sold as part ofCap Assembly only

Full unit description required followed by -H2005

3/4" BORE

3406-01-x

4348-x4351-x54398-x

2164-015766-01

——

2165-01

1972-0151972-0141972-0461972-0171972-0161972-0157113-001

7118

KEY PART DESCRIPTION1 Cap2 Tube3 Tierod & Nut Assembly4 Piston & Rod Assembly5 Head Assembly6 Seal Retainer7 Rod Seal8 Rod Seal Backup (HV only)9 Rear Bushing (HV only)10 Bushing Retainer (HV only)11 Front Bushing12 Rod Wiper13 Piston Seal14 Tube Seal15 Piston Seal Backup (HV only)16 Port Control Kit*17 Cushion Block Assembly

Kit** Ball Check Style (2 Cavity): A, AV HVKit** Check Seal (Single Cavity): A, AV

18 Stop Tube19 Spring Return Spring20 Stroke Adjustment Screw21 Stroke Adjustment Screw Nut22 Shock Pad Rod End 1/4" dia.

5/16" dia.3/8" dia.1/2" dia.

23 Shock Pad Cap End24 “RF” or “CF” Flange30 Rod End Jam Nut Standard Rod -F, -J

-L-G

Oversize Rod -F, -J-L-G

— Spherical End Rod EndCap End

NOTE: All part numbers listed are for standard units. Options may affect part numbers.Part number suffix (-1) indicates Buna-N seals.Part number suffix (-2) indicates Fluoro-Elastomer seals.

* Port Control Kit contains all parts required for one flow control function.** Cushion Block Kit contains parts for one cushion control function.

1" BORE

3406-02-x

4349-x4352-x54399-x

—2164-025766-02

—2165-02

1972-0171972-0161972-0151972-0191972-0181972-0177113-002

7120

1-1/8" BORE

3406-02-x

4350-x4353-x

54400-x

——

2164-035766-032165-03

1972-0191972-0181972-0171972-0211972-0221972-0207113-003

7126

6


®

MEDIUM DUTY CYLINDERSSERIES AV, HV; 1-3/8" BORE

SERIES AV, HV MEDIUM DUTY CYLINDERS1-3/8" BORE EXPLODED VIEW

SPRING RETURN

1

WITH -P HEAD

SHOCK PAD

-A CAP

CUSHION

CUSHION

38

3

11

2

28

2729

910

7

8

6

20

42221

3

20

1

35

1918

13 16 15

14

36

17 2324

2423

25

26

37

5

3031

12

21

22

7


PARTS LISTSERIES AV, HV; 1-3/8" BORE

Full unit description required followed by -H1100Full unit description required followed by -H1200Full unit description required followed by -H1300Full unit description required followed by -H1410Full unit description required followed by -H1000

Sold as partof Piston & RodAssembly only

Sold as part of Seal Kit orRepair Kit only

Full unit description required followed by -H1700Full unit description required followed by -H1600

Sold as part ofCap Assembly only


SERIES AV, HV MEDIUM DUTY CYLINDERS1-3/8" BORE PARTS LIST AND REPAIR KITS

1/2" ROD

3390-04-x3390-04-x

23702370

4602-021972-0191972-0201972-0182346-01

4080

7113-00471271332

KEY PART DESCRIPTION1 Head2 Cap3 Tube4 Tierod & Nut Assembly5 Piston & Rod Assembly6 Rod Retainer Nut7 Cushion Stud8 Cushion Retaining Ring9 Cushion Seal (AV only)

10 Cushion Disc (HV only)11 Cushion Spring12 Rod End Stud30 Piston31 Rod13 Rod Bushing14 Rod Seal Washer15 Rod Seal16 Rod Seal Backup Ring (HV only)17 Rod Wiper18 Bushing Seal19 Bushing Seal Backup Ring (HV only)20 Tube Seal21 Piston Seal22 Piston Seal Backup Ring (HV only)23 Port Control Kit*24 Cushion Control Kit*25 Shock Pad Rod End26 Shock Pad Cap End27 Stop Tube28 Spring29 Stop Tube Guide35 Rod End Jam Nut -G, -J

-F-L

36 Bushing Retainer37 Stroke Adjustment Screw38 Stroke Adjustment Nut— “T” Mounting Nut— “RF” or “CF” Flange— Spherical End Cap End

Rod End— “F” Mounting Bracket tab for -P caps

NOTE: All part numbers listed are for standard units. Options may affect partnumbers.Part number suffix (-1) indicates Buna-N seals.Part number suffix (-2) indicates Fluoro-Elastomer seals.

* Port Control Kit and Cushion Control Kit contain all parts required forone flow control function.

5/8" ROD

3390-04-x3390-04-x2449-05

2370

4602-021972-0201972-0211972-0572346-02

4080

——

1332

KITS

NOTE: Repair Kit contains parts to repair one cylinder.Cushion Repair Kit includes parts to rebuild one cushion, includinginternal seals and springs and a Cushion Control Kit.Seal Kit contains all seals, wiper seal, and backup rings.

KIT DESCRIPTIONRepair KitCushion Repair Kit AV

HVSeal Kit

1/2" ROD

3407-04-x3408-04-x

5/8" ROD

3407-04-x3408-04-x



8


SERIES A, AV, HV; 3/4, 1, 1-1/8, 1-3/8" BORETROUBLESHOOTING

The following troubleshooting chart is provided solely to serve as an aid for identifying the cause of a cylinder malfunction that may occur. The chart is divided into three columns: The “SYMPTOM” column describes the problem/behavior of the cylinder. The “PROBABLE CAUSE” column identifies possible sources of the problem. The “RECOMMENDED ACTION” column indicates the procedure/action to correct the problem.

NOTE: One of the most common problems causing poor cylinder performance is internal contamination. This is usually caused by Improperly filtered air or oil powering the cylinder or excessive use of thread sealant/thread tape when installing fittings into the cylinder ports.

Take Special Care To Prevent The Sealant Or Tape From Entering Into The Cylinder Ports.

SYMPTOM PROBABLE CAUSE RECOMMENDED ACTIONAir or oil leaking around piston rod. Cut or worn rod seal. Replace cylinder head bushings and rod seal.

Scratched, worn, or bent piston rod. Replace piston & rod.Air or oil leaking around ends of cylinder tube.

Tierods not tightened to specifications. Tighten tierods to specifications.

Cut defective tube seals. Replace tube seals.

Pressure spike in a hydraulic unit may have stretched tierods.

Replace tierod & nut assemblies.

Air or oil leaking around optional Port Control®, cushion adjustment needles, or ball check retainer.

Retaining nut not tightened to specifications. Tighten retaining nut to specifications.

Cut/defective gasket or O-ring seal. Replace gasket or O-ring seal.Air or oil leaking around optional stroke adjustment screw.

Self-sealing Hydro-Lok nut not tightened to specifications.

Tighten Hydro-Lok nut to specification.

Contaminants have collected around sealing portion of Hydro-Lok nut.

Clean contaminants from sealing area.

Seal on nut is cut or defective. Replace Hydro-Lok nut.Loss of power/continuous flow of air or oil evident in exhaust line.

Piston seal blow-by caused by:A. Scratched or worn cylinder tube.B. Cut or worn piston seals.

Replace cylinder tube and/or piston seals.

Scored/discolored piston rod. Internal lubrication dried out. (Usually due to extended service.)

Rebuild/overhaul complete cylinder.

Excessive side load on piston rod. Decrease weight of load, or support load with external bearing.

Cylinder not flat. (Head and cap are not square with each other.)

Flatten cylinder.

Erratic jumping/binding of piston rod during cycling.

Internal lubrication dried out. (Usually due to extended service.)

Rebuild/overhaul complete cylinder.

Ball check not seating properly; usually caused by internal contaminants. (Cylinders with optional Port Controls.)

Clean/rebuild ball check assembly.

Cylinder not flat. (Head and cap not square with each other.)

Flatten cylinder.

Optional cushions not functioning properly. Cushion seal in cushion block is cut or worn. Replace cushion seal O-ring in cushion block.

Cushion seal/disc cut or worn, spring broken or damaged on piston and rod assembly (1-3/8" bore only).

Replace piston and rod assembly. (Sold as assembly from factory.)

Scored cushion nose on piston (3/4, 1, and 1-1/8" Bores).

Replace piston and rod assembly. (Sold as assembly from factory.)

Internal contamination in ball check or adjusting needle cavities.*

Clean/rebuild ball check or adjusting needle assembly.

Optional Port Controls not functioning properly.

Internal contamination in adjusting needle cavity or in the ball check cavity which causes the ball check to seat improperly.

Clean/rebuild adjusting needle or ball check cavities.

Piston rod separates from piston or piston rod end breaks off.

Excessive end of stroke shock due to:A. Lack of proper shock absorbersB. High cycle speedC. Large load

Install cushions, external shock absorbers, or external stops.

Resize cylinder for the application.

* All Series A and AV Cylinders; 3/4", 1", and 1/1/8" bore with optional cushions do not contain a ball check assembly. For further information, consult PHD or your local distributor.

9


(B) Front Bushing(A) Rod Wiper

(D) Seal Retainer

(C) Rod Seal

Figure 1

Figure 2

Figure 3

Figure 4

GENERAL REPAIR/REBUILDING OF A BASIC CYLINDERSERIES A; 3/4, 1, 1-1/8" BORE

Figure 5

CYLINDER ASSEMBLY (Figure 2)

1. Install piston seal (A) on piston and rod assembly. 2. Install tube seals (B) onto cylinder head and cap. 3. Apply lubricant (see page 16) or equivalent around circumference of piston and

piston seal. 4. Insert piston and rod assembly (A) into cylinder tube (B). (Make sure piston seal

does not roll over or twist during insertion.) (Figure 3) 5. Apply lubricant (see page 16) or equivalent into the cylinder head cavity,

especially the piston rod seal. Also apply lubricant to threads on piston rod end. 6. Gently press piston rod into cylinder head while simultaneously spinning the

head. This procedure will avoid cutting the rod seal with the rod end threads. 7. Seat cylinder tube on the head. Place cap on the opposite end making sure both

ports are in their proper locations. 8. Install tierods. Snug up all tierods, but do not tighten. 9. With cylinder on a flat surface, use a flattening bar and rubber mallet to flatten

cylinder. (Head and cap are squared with each other.) (Figure 4) 10. Perform final torquing of tierods in the proper sequence (Figure 5) to the

recommended torque. (See Torque Specifications on page 16.) 11. Apply air to the cylinder. While cycling,

check for leakage around rod and tube seals and for piston seal blow-by.

NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed, and the parts to be reused are properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits.

Series A

(C)

(B) Tube Seal

(A) Piston Seal

3 2

1 4

BUSHING CYLINDER HEAD (Figure 1)

1. Insert Teflon rod wiper (A) all the way down into the cylinder head. 2. Using an arbor press, press front bushing (B) into head until it bottoms out

(Caution: Make sure bushing is not crushed or misaligned and rod wiper is not sheared.)

3. Insert rod seal (C) into cavity until it contacts the front bushing. (Note proper direction of the rod seal in the head.)

4. Using an arbor press, press rod seal retainer (D) into head until it is approximately 1/32" from the rod seal. (Do not crush rod seal between front bushing and rod seal retainer.)

(A) Piston & Rod

(B) Tube

10


REPAIR/REBUILDING WITH THE FOLLOWING OPTIONSSERIES A; 3/4, 1, 1-1/8" BORE

PORT CONTROLS (Figure 6)

1. With ball check and needle assembly removed, flush out cavities and corresponding internal porting in head or cap with appropriate parts cleaners. Using compressed air, blow out cavities to ensure all contaminants are removed.

2. Place a few drops of Rykon 32 oil or equivalent into ball check cavity. Drop steel ball (A) into ball check cavity. Using an appropriate punch, lightly peen the steel ball into the bottom of the cavity. (This procedure ensures correct seating of the steel ball and proper functioning of the ball check assembly.)

3. Place seal (B) onto ball check retainer (C). 4. Place spring (D) into cavity on ball check retainer. 5. Carefully thread the assembly into the cavity and tighten ball check retainer to the

recommended torque specifications (See page 16). 6. Check to make sure retainer nut is screwed all the way down on adjusting

needle. Place a few drops of Rykon 32 oil, or equivalent, into Port Control needle cavity. Thread needle assembly* (E) into cavity and tighten retaining nut (F) to recommended torque specifications (see page 16).

*NOTE: NeedleassemblyisshippedassembledinPortControlKit.Figure 6

CUSHION BLOCKS A (Figure 7)

1. For replacement of the ball check and cushion adjusting needle assemblies, follow steps 1 through 6 under Port Controls.

2. Insert cushion seal O-ring (B) into cavity on the cushion block.

NOTE: All Series A and AV cylinders 3/4, 1 and 1-1/8" bore with optional cushions do not contain a ball check assembly. For further information, consult Technical Data Bulletin C3.

SHOCK PADS (Figure 8)

Shock pads rarely need to be replaced, if ever. However, if replacement is necessary, the rod end shock pad is simply a press-fit on the piston rod. Slide the shock pad (A) onto piston rod until it contacts the piston. The cap end shock pad is also a press-fit into the inside diameter of the cylinder tube. Insert the shock pad (B) into the cap end of the tube to a depth of 1/16" from the end of

the tube.

STROKE ADJUSTMENT (Figure 9)

Screw the stroke adjustment screw (A) into the threaded cavity of the cylinder cap (B) as shown. Thread the self-sealing nut (C) onto the stroke adjustment screw making sure the seal portion of the nut is toward the cylinder cap.

NOTE: The face of the cap must be clean and free of nicks or scratches.

Figure 7

Figure 8

Figure 9

(D) Spring (A) Piston Seal

(B) Ball Check Retainer Seal(C) Ball Check Retainer

(E) Needle Assembly*(F)RetainingNut

(B) Cushion Seal O-Ring

(A) Cushion Block

(A) Rod End Shock Pad

(B) Cap End Shock Pad

(A) Stroke Adjustment Screw

(B) Cylinder Cap(C) Self-Sealing Nut

11


GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER


PORT CONTROLS

Follow steps 1 through 6 for Series A on page 10.

CUSHION BLOCKS

Follow steps 1 and 2 for Series A on page 10.

SHOCK PADS

Follow step 1 for Series A on page 10.

STROKE ADJUSTMENT

Follow step 1 for Series A on page 10.

MAGNETIC PISTON (Figure 11)

The magnetic band (A) on the piston rarely needs to be replaced. However, if unusual circumstances cause damage to the band, a complete piston and rod assembly with the magnetic band installed must be ordered from the factory.

SERIES AV; 3/4, 1, 1-1/8" BORE

SERIES AV; 3/4, 1, 1-1/8" BORE CYLINDERS WITH THE FOLLOWING OPTIONS:

Figure 10

BUSHING CYLINDER HEAD



1. Install piston seals (A) on piston (B). Note proper direction of piston seals. 2. Follow steps 2 through 11 for Series A on page 9.

Figure 11

Detail of Figure 10Series AV

(A) Block Vee Piston Seals

(B) Piston

(A) Magnetic Band

12



NOTE: The following steps are based on; the cylinder is disassembled, all seals and bushings are removed (with the exception of the cylinder head, see below), and the parts to be reused have been properly cleaned and inspected for defects. Reference pages 4 to 7 for replacement parts/repair kits.

Reference

SERIES HV; 3/4, 1, 1-1/8" BORE

Series HV


Due to the configuration of the double rod seal HV head assembly, the head is available only as a pre-bushed assembly from the factory. (Reference Head Assemblies page 5.) The only exceptions to this are a 3/4" bore with a 3/8" oversize rod, and a 1-1/8" bore with a 1/2" oversize rod.

Figure 12


1. Install piston seals (A) on piston (Note proper direction of piston seals). Install piston seal back-up rings (B) behind piston seals as shown.

2. Follow steps 2 through 10 for Series A on page 9. 3. Apply hydraulic pressure to the cylinder. While cycling, check for leakage around

rod and tube seals and for piston seal blow-by.

Detail of Figure 12

REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS

PORT CONTROLS


MAGNETIC PISTON

Reference step 1 for Series AV on page 11.

SERIES HV; 3/4, 1, 1-1/8" BORE

(A) Block-Vee Piston Seals

(B) Piston Seal Backup Rings

13


SERIES AV & HV; 1-3/8" BORE


Series AV & HV; 1-3/8" Bore


1. Insert rod seal back-up ring (A) (Series HV only) and rod seal (B) into cavity of rod bushing (C) as shown. (Note proper direction of rod seal in bushing,

Figure 13.) 2. Install bushing seal back-up ring (D) (Series HV only) and bushing seal (E) onto

outside of rod bushing. (Figure 13) 3. Insert rod wiper (F) into bushing retainer (I). (Note proper direction of the rod

wiper in the bushing retainer, Figure 13.) 4. Place rod seal washer (G) into bushing cavity in cylinder head (H). (Figure 13) 5. Apply lubricant (see page 16) or equivalent around diameter of bushing seal (E)

and inside diameter of Rod Seal (B). Insert rod bushing assembly into head. (Note proper direction of rod bushing assembly into head.)

6. Thread bushing retainer (I) into head and tighten to recommended torque specification. (See Torque Specifications page 16.)

Reference

F

ID

E CA

HB G

Figure 13Detail of Figure 13

A

CHead

B

C Cap

Figure 14Detail of Figure 14

CYLINDER ASSEMBLY

1. Install piston seals (A) on piston. (Note proper direction of piston seals on piston, Figure 14.) Install piston seal back-up rings (B) (Series HV only), behind piston seals as shown (Figure 14).

2. Install tube seals onto cylinder head and cap (Figure 14). 3. Apply lubricant (see page 16) or equivalent around circumference of

piston and piston seals.


14


GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER (cont.) 4. Insert piston and rod assembly (D) into cylinder tube (E) (Figure 15). Make sure

piston seals do not roll over or twist during insertion. 5. Apply lubricant (see page 16) or equivalent into the cylinder head cavity,

especially around the piston rod seal. Also apply lubricant to threads on piston rod end.

6. Gently press piston rod into cylinder head while simultaneously spinning the head. This procedure will avoid cutting the rod seal with the rod end threads.

7. Seat cylinder tube on the head. Place cap on the opposite end making sure both ports are in their proper locations.

8. Install tierods. Snug up all tierods but do not tighten. 9. With the cylinder on a flat surface, use a flattening bar and rubber mallet to

flatten the cylinder (Figure 16). (Head and cap are squared with each other.) 10. Perform final torquing of tierods in the proper sequence (Figure 17) to the

recommended torque. (See Torque Specifications on page 16.) 11. Apply air or hydraulic pressure to the cylinder. While cycling, check for leakage

around rod and tube seals and for piston seal blow-by.

Figure 15

Figure 16

Reference

Figure 17

PORT CONTROLS (Figure 18)

1. With ball check and needle assembly removed from the head and cap, flush out cavities and corresponding internal porting with appropriate parts cleaners. Using compressed air, blow out cavities to ensure all contaminants are removed.

2. Place a few drops of Rykon 32 oil, or equivalent, into ball check cavity. Drop the steel ball (A) into the ball check cavity. Using an appropriate punch, lightly peen the steel ball into the bottom of the cavity. (This procedure ensures correct seating of the steel ball for proper functioning of the ball check assembly.)

3. Place seal (B) onto ball check retainer (C). 4. Place spring (D) into cavity on ball check retainer. 5. Carefully thread the assembly into the cavity and tighten ball check retainer to

the recommended torque specification. (See Torque Specifications on page 16.) 6. Place a few drops of Rykon 32 oil, or equivalent, into Port Control needle

cavity. Thread needle assembly*(E) into cavity and tighten retaining nut (F) to recommended torque specification. (See Torque Specifications on page 16.)

*NOTE:NeedleassemblyisshippedassembledinPortControlKit.

Figure 18

SERIES AV & HV; 1-3/8" BORE CYLINDERS

3 2

1 4

ADC

EB

F

(A) Piston & Rod Assembly

(B) Tube

REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS

15


SERIES AV & HV; 1-3/8" BORE (cont.)

Figure 22

Figure 21

Figure 19

Figure 20

STROKE ADJUSTMENT (Figure 21)

Screw the stroke adjustment screw (A) (available on Series AV only) into thethreaded cavity of the cylinder cap (B) as shown. Thread the self-sealing nut(C) onto the stroke adjustment screw making sure the seal portion of the nutis toward the cylinder cap. Face of cap must be clean and free of nicks or scratches.

MAGNETIC PISTON (Figure 22)

The magnetic band (A) on the piston rarely needs to be replaced. However, if unusual circumstances cause damage to the band, a complete piston and rod assembly with the magnetic band installed must be ordered from the factory.

SHOCK PADS (Figure 20)

Shock pads (available on Series AV only) rarely need to be replaced, if ever. However, if replacement is necessary, the rod end shock pad is simply a press-fit onto the piston rod. Slide the shock pad (A) onto the piston rod until it contacts the piston. The cap end shock pad is also a press-fit onto a stud located on the piston. Insert the shock pad (B) onto the stud until it contacts the piston.

CUSHION

For replacement of the cushion adjusting needle in the head or cap, follow step 6, page 10, under “Port Controls”. NOTE: If cushion malfunction is due to wear or damage of the components on the cushion poppet assembly (A) on the piston and rod assembly (Figure 19), a complete piston and rod assembly must be ordered from the factory. (A)

A

B

A

B

C

A

16


TORQUE SPECIFICATIONS

TORQUE

LUBRICATIONSERIES A & AV

All air cylinders are permanently lubricated at the factory and can be used for dry air service, if desired. When rebuilding an air cylinder or when lubrication is required due to adverse conditions, PHD recommends the following mixture to be used:

•50%STPoiland50%AmocoRykon32oil(orequivalents).

NOTE: This lubricant mixture is also recommended for lubricating the piston and rod seals on hydraulic units units when rebuilding the cylinder.

STP is a registered trademark of STP Corporation.Amoco Rykon 32 is a registered trademark of Amoco Oil Company.

TORQUE (in-lb)PART DESCRIPTION 3/4" 1" 1-1/8" 1-3/8" BORE BORE BORE BORENUT, TIEROD 17 30 40 100RETAINER,BALLChECK,&NEEDLE 25 40 40 40(PORT CONTROL & CUSHION)RETAINER, BUSHING — — — 310ROD, PISTON & DOUBLE ROD 75 100 125 140STUD, CUSHION — — — 75STUD, ROD END — — — 140STUD, ROD END (OVERSIZE) — 140 140 140PISTON ROD NUT — — — 200“F”MOUNTINGBRACKETSCREWS 30 50 — —BOLTED ON FLANGE SCREWS 17 19 34 110BUMPER MOUNTING SCREWS 17 30 30 30SPHERICAL ROD END NUTS 75 100 125 200TRUNNION PINS 25 40 40 —LONGSTROKEUNITMOUNTINGSCREWS — 50 76 170NUT, TIEROD EXTENSION RR, RC, RRC 17 30 40 100

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www.phdinc.com • [email protected]

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Tel. +49 (0)2401 805 230 • Fax +49 (0)2401 805 232www.phdinc.com • [email protected]

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