Service Manual

Rotary Actuator
 ROTARY ACTUATOR
1. PRELIMINARY REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1. Safety ...................................... 3

1.2. About this booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. ROTARY ACTUATOR : EXPLANATION . . . . . . . . . . . . . . . . . . . 7

4. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1. Housing ...................................... 9

5.2. Shaft ...................................... 9

6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2. Piston ...................................... 11

6.3. Shaft ...................................... 12

6.4. End cap ...................................... 12

6.5. Testing ...................................... 12

6.6. Greasing ...................................... 13

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ROTARY ACTUATOR PRELIMINARY REMARKS

1. PRELIMINARY REMARKS
1.1. Safety
The informations contained in this manual must be studied and thoroughly assimilated
before undertaking any maintenance work on the equipment

Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.

Danger. Operation, maintenance and adjustments are only allowed to

persons with specific training in operation and maintenance of the
equipment. Read the operating and maintenance instructions before
using or servicing the equipment.

Danger. Before starting any maintenance operation ensure that the

machine is in a safe location with good safety, ventilation and lighting
conditions. Ensure that lifting equipments and pedestals are
compatible with elements’ weight. Follow all the safety instructions
WARNING and ware safety protections as gloves, goggle, helmet, safety boots,
ear protectors.

Danger. Before any operation stabilize and fix steadily all the elements
on suitable pedestals. Stop the power packs, switch the general power
breaker. Place a tag or a board to warn other members of the
personnel that maintenance work on the machine is in progress.

Danger. Pressurized oil jets could cause severe injuries. Before any
operation on hydraulic circuit, STOP the power packs and release
remaining pressure in components by operating hydraulic control
levers several times. Always release the static pressure in cylinders
before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT.

Danger. While tests are in progress, do not allow any other member of
the personnel to stand in the area surrounding the machine. Stay at the
control station to be able to stop the movement and switch off the
power pack.

Danger. Maintenance, adjustment and repairs are restricted to

qualified personnel with special training for the particular equipment.
Always read the instructions carefully before starting any maintenance
work.

Caution. Always use suitable tools and work in a clean place when
dismantling and assembling hydraulic components. After removing
cylinders the hydraulic inlet/outlet ports must be plugged to prevent
dirt and air intrusion during operation.

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PRELIMINARY REMARKS ROTARY ACTUATOR
Danger. The operator must always wear required personal protection,
such as safety helmet, protective overall, safety boots, hearing
protectors, safety goggles etc.

Danger. Danger of high pressure oil jets.

High pressure oil jets can cause serious personal injuries.
Release the pressure in the hydraulic circuits before opening caps or
connections.
(Accumulator, Cylinder and Hydraulic circuit)
Danger. Danger of hot surface.
Hot surface can cause serious injuries.
Components rod, shank or hydraulic component can be hot and before
starting a maintenance work, please let them cool off.
WARNING
The operator must have adequate wears as gloves.

Danger. Crushing hazard : do not stay in dangerous area, for instance:

central articulation, front chassis and rear chassis.

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ROTARY ACTUATOR PRELIMINARY REMARKS

SAFETY

Always follow the marked safety instructions, and

WARNING

observe caution while working.

The following safety instructions are general rules.

Keep tools and drilling

equipment clean.
WARNING

Do not attempt any such repairs or adjustments that you do not fully
understand.
WARNING
WARNING

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.
Make sure then that:
WARNING

- no danger is caused to anybody.

- the machine can be immediately stopped when necessary.
- the powerpack is stopped again before the repair-work is continued.

Before starting any repair-work move away from the area where you have just
drilled.
WARNING

Use proper tools.

WARNING

Always wear protective clothing, eye protection, earmuffs, safety footwear, and
other safety equipment required by the work.
WARNING

1.2. About this booklet

The present manual is destined for the use of personnel in charge of carrying out,
servicing and maintenance operations on Jumbos.
It contains maintenance operations schedule and operating methods concerning the
main elements of the ROTARY ACTUATOR.
Note that servicing and maintenance operations must be carried out by personnel
with the required qualifications, technical knowledge, and proper training on the
machine.

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MAIN COMPONENTS ROTARY ACTUATOR
2. MAIN COMPONENTS

10
7 6

2 5

2’ 2’’
10 9

E2
4
3
E1 10
1
8

11

1 - ROTARY ACTUATOR HOUSING

2 - SHAFT (2’ MOUNTING FLANGE, 2’’ BEARING TUBE
3 - PISTON SLEEVE
4 - PISTON
5 - END CAP
6 - END CAP ALLEN SCREW
7 - RADIAL BEARING
8 - LARGE RADIAL
9 - THRUST RING
10 - GREASE NIPPLE
11 - SAFETY HYDRAULIC VALVE

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ROTARY ACTUATOR ROTARY ACTUATOR : EXPLANATION

3. ROTARY ACTUATOR : EXPLANATION

Fluid entering Port E2 under pressure will bear on piston (4) and force piston sleeve (3)
as indicated by the arrows.
The left-handed spline of piston sleeve (3) will combine with the right-handed spline of
the shaft (2) and cause rapid counter-clockwise rotation of the housing (1).
Fluid entering Port E1 will reverse this rotation.

Displacement and torque are identical for clockwise and counter-clockwise rotation.

The housing is supported radially by the large radial bearing (8) and the radial bearing
(7). Axially, the shaft is separated from the housing by two thrust rings (9).

End cap (5) is adjusted for axial clearance and locked in position by the four cap screws
(6).
It lock the shaft in rotation by the end shaft splin.

7 6
2
5

E2
4
3
E1
1
8

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DISASSEMBLY ROTARY ACTUATOR
4. DISASSEMBLY

Place on a clean work bench with room to place the internal parts as they are removed.

• Remove the safety hydraulic

N valves (11) and the grease
3 nipples (10).
2
• Remove the screws (6).

• Remove the cap (7).

• Unscrew the end cap (5).

(Viewed from the mounting flange)

Caution. Note the orientation between the spline teeth, as this will
greatly simplify actuator timing upon reassembly. See item (N).

The shaft (2) is now free to slide out of engagement with the piston sleeve (3).

After removing the shaft, the piston assembly can now be moved out of the housing.
Remove all seals and wear strips from their grooves except static piston seals. These
seals generaly do not require replacement.

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ROTARY ACTUATOR INSPECTION

5. INSPECTION

Clean all the parts thoroughly and inspect for wear.

A small amount of wear in the spline teeth will have little effect on the actuator strength.
New spline sets are manufactured with a backlash of about 0,13mm (0.005’) per mating
set. After a long service, a backlash of about 0,38mm (0.015’) per set may still be
acceptable.

5.1. Housing

I
Check the ring gear (12) for wear and
12
weld damage to the pins (13).
13
Inspect the cylinder bore for wear and
scratches. The surface finish should be
32 RMS or better, rehone if necessary.

5.2. Shaft

Visualy check the shaft revolution

surface.

Rough and grooved shaft journals

require shaft replacement.

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ASSEMBLY ROTARY ACTUATOR
6. ASSEMBLY
6.1. Preparation

Wash all the parts thoroughly in cleaning solvent and blow dry. Coat all sealing and
working surfaces with good grade hydraulic oil.

15
• install seals (14) in piston sleeve and piston.

14

• Install new bearing (15) on piston.

4
3

16
• Install new bearing and new seals on end cap
17 (4).

NOTE: the lip of exclusion seal (16) must

be directed outward, the lip of high pressure
seals (17) inward.

17
• Install new bearings and new seals on shaft-
mounting flange (2’).

NOTE: the lip of exclusion seal (16) must

be directed outward, the lip of high pressure
5 seals (17) inward.

Install the thrust rings (9) on shaft and end cap, coat the bearings with good grease
before sliding on the shaft and end cap.

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ROTARY ACTUATOR ASSEMBLY

6.2. Piston

END CAP SIDE

SHAFT SIDE

Looking mounting flange side, install the piston in timed relation to the housing. Apply
firm pressure as the new seals and bearings enter the housing and become compressed
by the housing chamber.

Caution. Do not cock the sleeve too much any one way, for it will mark
the cylinder bore.

The timing marks (small punch marks on the face of each gear) must be lined up for
proper drill
feed orientation.

For easier shaft installation, push the piston untill it makes contact to the ring gear.

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ASSEMBLY ROTARY ACTUATOR
6.3. Shaft
The shaft is installed by again aligning the proper punched timing marks. Temporary
taping (masking tape works well) of threaded portion of shaft will help installation past
the shaft seals.
• Apply antiseize compound to :
• Threaded and surrounding areas of end cap (5).
• Thrust bearing area of the shaft (2).

6.4. End cap

Torque the end cap to 80Nm (60 ft.lb), such that the actuator begins rotation at
approximately 7bar (100 PSI).

If the end cap is torqued too high, the actuator may take as much as 20bar (300 PSI) to
rotate.

If the end cap is not torqued high enough, axial motion between housing and shaft may
result. This axial motion can damage the ring gear, piston, seals,sleeve and/or shaft.

Install the cap and tighten the 4 screws to lock the end cap in position.

NOTE: END CAP TORQUE SHOULD BE CHECKED AT LEAST EVERY 800 HOURS
OR ONCE A YEAR. IF END PLAY (axial motion) IS OBSERVED, TIGHTEN END
CAP.

6.5. Testing

To test for leakage, connect a hydraulic hose only to port E2. Pressurize to 200bar
(3000PSI).
No oil should seep from port E1 or from around end cap.

Repeat test for pressurizing port E1 and check for leakage out of port E2 and around
shaft mounting flange.

• Install the hydraulic safety valves and pipe back to the actuator.
• Install the grease nipples and grease relief valve.

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ROTARY ACTUATOR ASSEMBLY

6.6. Greasing

During the greasing, make sure that the surplus of grease seep out by the two safety
hydraulic valves (11) («grease relief valves»). A too high pressure of grease can block or
damage the rotary actuator.

Proper grease through grease nipples

Surplus of grease through safety valves

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ASSEMBLY ROTARY ACTUATOR

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