Post on 19-Jan-2021
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
®
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
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
Full unit description required followed by -H2005
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
Full unit description required followed by -H9010
Full unit description required followed by -H9000
8
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
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
NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.MDCREPAIR
(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
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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
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GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER
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.
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
Follow steps 1 through 4 for Series A on page 9.
CYLINDER ASSEMBLY (Figure 10)
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
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GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER
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
BUSHING CYLINDER HEAD
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
CYLINDER ASSEMBLY (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
Follow steps 1 through 6 for Series A on page 10.
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
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SERIES AV & HV; 1-3/8" BORE
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 AV & HV; 1-3/8" Bore
BUSHING CYLINDER HEAD
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.
GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER
14
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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
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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
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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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