MEDIUM DUTY CYLINDERS REPAIR MANUAL

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MEDIUM DUTY CYLINDERS REPAIR MANUAL

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

NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

2NO RETURNS WITHOUT PRIOR AUTHORIZATION FROM PHD, INC.

PART NO.: 6441-801

© Copyright 2019, by PHD, Inc. All Rights Reserved. Printed in the U.S.A.

PAGEMODEL NOMENCLATURE 2-3PARTS LISTS AND REPAIR KITS 4TROUBLESHOOTING 5REPAIR / REBUILD: Series A; 3/4", 1", 1-1/8" Bore Cylinders 6-7 Series AV; 3/4", 1", 1-1/8" Bore Cylinders 8 Series HV; 3/4", 1", 1-1/8" Bore Cylinders 9 Series AV & HV; 1-3/8" Bore Cylinders 10-12TORQUE SPECIFICATIONS, LUBRICATION 12

MODEL NOMENCLATURE

G-M-Vx - -SC AV F 1 2 P D 3/8 ROD- -

NOTES:1) For double rod cylinders, rod end options will be applied to both ends of cylinder.2) For double rod cylinders, -_K extension will be applied to one end only (head end/primary mounting end).3) Marked options provide additional cylinder flexibility, but may alter the dimensions.

TO ORDER SPECIFY:Spring Return/Double Rod End, Series, Mounting Style, Bore Size, Stroke, Port Control®, and any Options. Also specify rod diameter if non-standard. Rod couplings and mounting attachments must be ordered separately.

OVERSIZE RODTo be specified only when using a non-standard diameter. See catalog.

CUSHION OR SHOCK PADD - Cushions on both endsDR - Cushion on rod endDC - Cushion on cap endB - Shock Pads on both endsBR - Shock Pad on rod endBC - Shock Pad on cap end(Cushions, Shock Pads, and Spring Return are not available on the same end of cylinder. Shock Pads and 3/4", 1", and 1-1/8" Cushions not available on Series HV.)

STANDARD STROKE LENGTHS3/4" BORE1/4" to 12"

1" BORE1/4" to 18"

1-1/8" BORE1/4" to 18"

All in 1/4" incrementsConsult PHD for longer lengths.

BORE SIZE3/4" BORE

1/4" Std. Rod Dia.1/4-28 Thread

1" BORE5/16" Std. Rod Dia.

5/16-24 Thread

1-1/8" BORE3/8" Std. Rod Dia.

3/8-24 Thread

SERIESAV - 150 psi AirHV - 1500 psi Hyd.A - 150 psi Air

OPTIONSA - Stroke Adjustment, 1/2" of adjustment standard (not available on Series HV)E - Magnetic Piston for PHD Hall Effect Switches (not available on Series A)G - #2 Rod End (see note 1)I - #4 Rod End, Female thread on rod (see note 1)H47 - Rodlok (Rod clamping device installed. Not available with Z1 or on HV. See option page.)J - #2X Rod End, twice as long as standard thread_K - Extra Rod Extension, in 1/8" increments (see note 2)L - Coarse Thread Rod End (see note 1)M - Magnetic Piston for PHD Reed Switches (not applicable on Series A)N - Plain Rod End (see note 1)Q - Port in Position #1, must be specified if required with mounting style “F” (“F” mounting tab on cap end)R - Ports in Position #2T - Ports in Position #3 (“F” mounting tab on cap end)U - Ports in Position #4V - Fluoroelastomer SealsW - Close Tolerance Stroke, ± 0.005" stroke lengthY - SAE Ports (Series HV Only) 3/4, 1, 1-1/8" boreZ1 - Electroless Nickel Plate all ferrous parts excluding Rod Ends

SPRING RETURNSC - Spring on cap endSR - Spring on rod end (Strokes available in 1/4" increments up to 6".)

and/orDOUBLE ROD END

D - Double Rod End CylindersLeave blank if not needed.

MOUNTING STYLEF - Foot Mount, c’bored thru holesB - Bottom Mount, tapped holes in head and capR - Rod Mount, tapped holes on front face of headT - Thread Mount, threaded snout on head (shipped with mounting nut)RF - Rod End FlangeCF - Cap End FlangeL - Pilot Mount, threaded snout and pilot diameter on head (shipped with mounting nut)P - Pivot Mount, pivot on capRR - Tierod Mount, tierods extend out rod endRC - Tierod Mount, tierods extend out cap endRRC - Tierod Mount, tierods extend out both ends

PORT CONTROL®

BUILT-IN METEROUT FLOW

CONTROL VALVEP - Flow control on both endsPR - Flow control on head endPC - Flow control on cap end

PROXIMITY SWITCH MOUNTING BRACKETSSERIES BORE SIZE NO.

AV, HV3/4" -311" -32

1-1/8" -33

CONTENTS

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


PART NO.: 6441-801

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 replaced 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.

MODEL NOMENCLATURE

M-Vx - -SC AV F 1-3/8 2 P D 5/8 ROD- -

NOTES:1) For double rod cylinders, rod end options will be applied to both ends of cylinder.2) For double rod cylinders, -_K extension will be applied to one end only (head end/primary mounting end).3) Marked options provide additional cylinder flexibility, but may alter the dimensions.

TO ORDER SPECIFY:Series, Mounting Style, Bore Size, Stroke, Port Control®, and any Options. Also specify rod diameter if non-standard. Rod couplings and mounting attachments must be ordered separately.

OVERSIZE RODTo be specified only when using a non-standard diameter. See catalog.

CUSHION OR SHOCK PADD - Cushions on both endsDR - Cushion on rod endDC - Cushion on cap endB - Shock Pads on both endsBR - Shock Pad on rod endBC - Shock Pad on cap end(Cushions, Shock Pads, and Spring Return are not available on the same end of cylinder.)

STANDARDSTROKE LENGTHS

1-3/8" BORE1/2" to 24"

In 1/2" incrementsConsult PHD forlonger lengths.

BORE SIZE1-3/8" BORE

1/2" Std. Rod Dia.3/8-24 Thread

SERIESAV - 150 psi AirHV - 1500 psi Hyd.

OPTIONSA - Stroke Adjustment, 1/2" of adjustment standard (not available on Series HV)E - Magnetic Piston for PHD Hall Effect SwitchesF - #1 Rod End (see note 1)I - #4 Rod End, Female thread on rod (see note 1)H47 - Rodlok (Rod clamping device installed. Not available with Z1 or on HV.)J - #2X Rod End, twice as long as standard thread_K - Extra Rod Extension, in 1/8" increments (see note 2)L - Coarse Thread Rod End (see note 1)M - Magnetic Piston for PHD Reed SwitchesN - Plain Rod End (see note 1)R - Ports in Position #2T - Ports in Position #3U - Ports in Position #4V - Fluoroelastomer SealsW - Close Tolerance Stroke, ± 0.005" stroke lengthZ1 - Electroless Nickel Plate all ferrous parts excluding Rod Ends

SPRING RETURNSC - Spring on cap endSR - Spring on rod end (Strokes available in 1/4" increments up to 6".)

and/orDOUBLE ROD END

D - Double Rod End CylindersLeave blank if not needed.

MOUNTING STYLEF - Foot MountB - Bottom Mount, tapped holes in head and capR - Rod Mount, tapped holes on front face of headT - Thread Mount, threaded snout on head (shipped with mounting nut)RF - Rod End FlangeCF - Cap End FlangeK - Clevis Mount, clevis on capTR - Trunnion MountRR - Tierod Mount, tierods extend out rod endRC - Tierod Mount, tierods extend out cap endRRC - Tierod Mount, tierods extend out both ends

PORT CONTROL®

BUILT-IN METEROUT FLOW

CONTROL VALVEP - Flow control on both endsPR - Flow control on head endPC - Flow control on cap end

PROXIMITY SWITCH MOUNTING BRACKETSSERIES BORE SIZE NO.AV, HV 1-3/8" -34

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


PART NO.: 6441-801PARTS LISTS AND REPAIR KITS

PARTS LISTS AND REPAIR KITS

1. Visit www.phdinc.com/av.

2. Click on the CAD | Ordering Data | Parts tab.

3. Enter your part number into the configurator.

4. Click the Get Replacement Parts button.

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PART NO.: 6441-801

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

TROUBLESHOOTING

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 and 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 and 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.


PART NO.: 6441-801

Figure 2

(B) Tube Seal

(A) Piston Seal

Figure 1

(B) Front Bushing(A) Rod Wiper

(D) Seal Retainer

(C) Rod Seal(C)

Figure 3

(A) Piston & Rod

(B) Tube

Figure 4

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

3 2

1 4

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 12) 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 12) 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 12.)

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 page 4 for replacement parts/repair kits.

Series A

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.)


PART NO.: 6441-801REPAIR/REBUILD 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 12).

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 12). *NOTE: Needle assembly is shipped assembled in Port Control Kit.

(D) Spring (A) Piston Seal

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

(E) Needle Assembly*(F)RetainingNut

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 at litstore.phdinc.com.

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.

(B) Cushion Seal O-Ring

(A) Cushion Block

Figure 7

(A) Rod End Shock Pad

(B) Cap End Shock Pad

Figure 8

(A) Stroke Adjustment Screw

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

Figure 9


PART NO.: 6441-801GENERAL REPAIR/REBUILD OF BASIC CYLINDER


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 7.

CUSHION BLOCKS Follow steps 1 and 2 for Series A on page 7.

SHOCK PADS Follow step 1 for Series A on page 7.

STROKE ADJUSTMENT Follow step 1 for Series A on page 7.

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

(A) Block Vee Piston Seals

(B) Piston

Figure 10

BUSHING CYLINDER HEAD Follow steps 1 through 4 for Series A on page 6.

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 6.

(A) Magnetic Band

Figure 11

Detail of Figure 10

Series AV


PART NO.: 6441-801GENERAL REPAIR/REBUILD OF 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 page 4 for replacement parts/repair kits.

Reference

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

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 parts lists online, see page 4.) 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

(A) Block-Vee Piston Seals

(B) Piston Seal Backup Rings

Detail of Figure 12

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

REPAIR/REBUILD WITH THE FOLLOWING OPTIONS

PORT CONTROLS Follow steps 1 through 6 for Series A on page 7.

MAGNETIC PISTON Reference step 1 for Series AV on page 8.

Series HV

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 6.

3. Apply hydraulic pressure to the cylinder. While cycling, check for leakage around rod and tube seals and for piston seal blow-by.


PART NO.: 6441-801

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


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 12) 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 on page 12.)

Reference

F

ID

E CA

HB G

Figure 13 Detail 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 12) or equivalent around circumference of piston and piston seals.

GENERAL REPAIR/REBUILD OF BASIC CYLINDER


PART NO.: 6441-801

Reference

GENERAL REPAIR/REBUILD OF BASIC CYLINDER (cont.)

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

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 12) 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 12.)

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

(A) Piston & Rod Assembly

(B) Tube

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 12.)

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 12.)

*NOTE: Needle assembly is shipped assembled in Port Control Kit.

ADC

EB

F

Figure 18

REPAIR/REBUILD WITH THE FOLLOWING OPTIONS

Figure 16

3 2

1 4

Figure 17


PART NO.: 6441-801

TORQUESERIES A & AVTORQUE SPECIFICATIONS

LUBRICATION

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% STP oil and 50% Amoco Rykon 32 oil (or equivalents).

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.

3/19 10891

TORQUE (in-lb)PART DESCRIPTION 3/4" BORE 1" BORE 1-1/8" BORE 1-3/8" BORENUT, TIEROD 17 30 40 100RETAINER, BALL CHECK, & NEEDLE (PORT CONTROL & CUSHION) 25 40 40 40

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” MOUNTING BRACKET SCREWS 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 —LONG STROKE UNIT MOUNTING SCREWS — 50 76 170NUT, TIEROD EXTENSION RR, RC, RRC 17 30 40 100

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

Figure 19

(A)

Figure 20

A

B

Figure 21

A

B

C

Figure 22

A

STROKE ADJUSTMENT (Figure 21)

Screw the stroke adjustment screw (A) (available on Series AV only) 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. 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 7, 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.

MEDIUM DUTY CYLINDERS REPAIR MANUAL

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