MEDIUM DUTY CYLINDERS REPAIR MANUAL - Phdinc

SERIES AV, HV MEDIUM DUTY CYLINDERS PARTS LIST 1-3/8" BORE SERIES PARTSAV,LIST AND BORE REPAIR KITS HV; 1-3/8" KITS KEY 1 2 3 4 5 6 7 8 9 10 11 12 30 31 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 35 36 37 38 — — — — NOTE: PART DESCRIPTION 1/2" ROD 5/8" ROD Full unit description required followed by -H1100 Full unit description required followed by -H1200 Full unit description required followed by -H1300 Full unit description required followed by -H1410 Full unit description required followed by -H1000 Head Cap Tube Tierod & Nut Assembly Piston & Rod Assembly Rod Retainer Nut Cushion Stud Cushion Retaining Ring Sold as part Cushion Seal (AV only) of Piston & Rod Cushion Disc (HV only) Assembly only Cushion Spring Rod End Stud Piston Rod Rod Bushing Rod Seal Washer Rod Seal Sold as part Rod Seal Backup Ring (HV only) of Seal Kit or Rod Wiper Repair Kit only Bushing Seal Bushing Seal Backup Ring (HV only) Tube Seal Piston Seal Piston Seal Backup Ring (HV only) 3390-04-x 3390-04-x Port Control Kit* 3390-04-x 3390-04-x Cushion Control Kit* 2370 2449-05 Shock Pad Rod End 2370 2370 Shock Pad Cap End Full unit description required followed by -H1700 Stop Tube Full unit description required followed by -H1600 Spring 4602-02 4602-02 Stop Tube Guide 1972-019 1972-020 Rod End Jam Nut -G, -J 1972-020 1972-021 -F 1972-018 1972-057 -L 2346-01 2346-02 Bushing Retainer Sold as part of Stroke Adjustment Screw Cap Assembly only Stroke Adjustment Nut 4080 4080 “T” Mounting Nut Full unit description required followed by -H2005 “RF” or “CF” Flange 7113-004 — Spherical End Cap End 7127 — Rod End 1332 1332 “F” Mounting Bracket tab for -P caps KIT DESCRIPTION Repair Kit Cushion Repair Kit AV HV Seal Kit 5/8" ROD 1/2" ROD Full unit description required followed by -H9010 3407-04-x 3407-04-x 3408-04-x 3408-04-x Full unit description required followed by -H9000 NOTE: Repair Kit contains parts to repair one cylinder. Cushion Repair Kit includes parts to rebuild one cushion, including internal seals and springs and a Cushion Control Kit. Seal Kit contains all seals, wiper seal, and backup rings. 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 and Cushion Control Kit contain all parts required for one flow control function. 7 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

TROUBLESHOOTING SERIES A, AV, HV; 3/4, 1, 1-1/8, 1-3/8" BORE 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 ACTION Air 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. 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. Retaining nut not tightened to specifications. Tighten retaining nut to specifications. Cut/defective gasket or O-ring seal. Replace gasket or O-ring seal. 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. Air or oil leaking around ends of cylinder tube. Air or oil leaking around optional Port Control , cushion adjustment needles, or ball check retainer. Air or oil leaking around optional stroke adjustment screw. 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. 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. 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 absorbers B. High cycle speed C. Large load Install cushions, external shock absorbers, or external stops. Erratic jumping/binding of piston rod during cycling. Optional cushions not functioning properly. 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. 8 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES A; 3/4, 1, 1-1/8" 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 A BUSHING CYLINDER HEAD (Figure 1) 1. 2. 3. 4. Insert Teflon rod wiper (A) all the way down into the cylinder head. 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.) Insert rod seal (C) into cavity until it contacts the front bushing. (Note proper direction of the rod seal in the head.) 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.) (B) Front Bushing (A) Rod Wiper (C) Rod Seal (C) (D) Seal Retainer Figure 1 CYLINDER ASSEMBLY (Figure 2) (A) Piston Seal 1. 2. 3. Install piston seal (A) on piston and rod assembly. Install tube seals (B) onto cylinder head and cap. 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 1 4 seals and for piston seal blow-by. 3 Figure 5 (B) Tube Seal Figure 2 (A) Piston & Rod (B) Tube Figure 3 2 Figure 4 9 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS SERIES 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 (D) Spring (A) Piston Seal ball check assembly.) (E) Needle Assembly* 3. Place seal (B) onto ball check retainer (C). (F) 4. Place spring (D) into cavity on ball check retainer. Retaining Nut 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 (B) Ball Check Retainer Seal needle. Place a few drops of Rykon 32 oil, or equivalent, into Port Control needle (C) Ball Check Retainer cavity. Thread needle assembly* (E) into cavity and tighten retaining nut (F) to recommended torque specifications (see page 16). Figure 6 *NOTE: Needle assembly is shipped assembled in Port Control Kit. CUSHION BLOCKS A (Figure 7) 1. 2. (A) Cushion Block For replacement of the ball check and cushion adjusting needle assemblies, follow steps 1 through 6 under Port Controls. 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. (B) Cushion Seal O-Ring Figure 7 SHOCK PADS (Figure 8) (A) Rod End Shock Pad 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. (B) Cap End Shock Pad Figure 8 STROKE ADJUSTMENT (Figure 9) (A) Stroke Adjustment Screw 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. (B) Cylinder Cap (C) Self-Sealing Nut Figure 9 10 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES AV; 3/4, 1, 1-1/8" 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 Detail of Figure 10 BUSHING CYLINDER HEAD (A) Block Vee Piston Seals Follow steps 1 through 4 for Series A on page 9. CYLINDER ASSEMBLY (Figure 10) 1. 2. Install piston seals (A) on piston (B). Note proper direction of piston seals. Follow steps 2 through 11 for Series A on page 9. (B) Piston Figure 10 SERIES AV; 3/4, 1, 1-1/8" BORE CYLINDERS WITH THE FOLLOWING OPTIONS: 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 (A) Magnetic Band 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. Figure 11 11 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER SERIES HV; 3/4, 1, 1-1/8" BORE 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. 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. Reference 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. (A) Block-Vee Piston Seals (B) Piston Seal Backup Rings Figure 12 Detail of Figure 12 REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS SERIES HV; 3/4, 1, 1-1/8" BORE PORT CONTROLS Follow steps 1 through 6 for Series A on page 10. MAGNETIC PISTON Reference step 1 for Series AV on page 11. 12 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

GENERAL REPAIR/REBUILDING OF A BASIC CYLINDER 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. 2. 3. 4. 5. 6. 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.) Install bushing seal back-up ring (D) (Series HV only) and bushing seal (E) onto outside of rod bushing. (Figure 13) Insert rod wiper (F) into bushing retainer (I). (Note proper direction of the rod wiper in the bushing retainer, Figure 13.) Place rod seal washer (G) into bushing cavity in cylinder head (H). (Figure 13) 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.) Thread bushing retainer (I) into head and tighten to recommended torque specification. (See Torque Specifications page 16.) I D Reference E C B G F Detail of Figure 13 A H Figure 13 CYLINDER ASSEMBLY 1. 2. 3. 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). Install tube seals onto cylinder head and cap (Figure 14). Apply lubricant (see page 16) or equivalent around circumference of Head piston and piston seals. A C C Cap B Figure 14 Detail of Figure 14 13 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

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. (A) Piston & Rod Assembly (B) Tube Figure 15 Figure 16 Reference 1 4 3 2 Figure 17 REPAIR/REBUILDING WITH THE FOLLOWING OPTIONS SERIES AV & HV; 1-3/8" BORE CYLINDERS PORT CONTROLS (Figure 18) 1. 2. 3. 4. 5. 6. C 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. 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.) Place seal (B) onto ball check retainer (C). Place spring (D) into cavity on ball check retainer. Carefully thread the assembly into the cavity and tighten ball check retainer to the recommended torque specification. (See Torque Specifications on page 16.) 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.) D A B E F Figure 18 *Note: Needle assembly is shipped assembled in Port Control Kit. 14 MDCREPAIR NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

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

SERIES A, AV, HV; 3/4, 1, 1-1/8" BORE SERIES A, AV, HV MEDIUM DUTY CYLINDERS 3/4, 1, 1-1/8" BORE PARTS LIST AND REPAIR KITS REPAIR KITS Full unit description required followed by -H9010 NOTE: Repair kits include all seals and bushings. SEAL KITS Full unit description required followed by -H9000 NOTE: Seal kits include all seals and backup rings.