s05 rotary actuator 360°

7/23/2019 S05 Rotary Actuator 360°

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ROTARY ACTUATOR

MAINTENANCE MANUAL

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80



A 06-2004 AR-MC-FLROTARY 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 11

6/4 END CAP 12

6/5 TESTING 13

6/6 GREASING 13



A 06-2004 AR-MC-FL ROTARY ACTUATOR


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

WARNING Operation, maintenance and adjustments are only allowed to persons withspecific training in operation and maintenance of the equipment. Read the operatingand maintenance instructions before using or servicing the equipment.

WARNING: Before starting any maintenance operation ensure that the machine is in a

safe location with good safety, ventilation and lighting conditions. Ensure that liftingequipments and pedestals are compatible with elements’ weight. Follow all the safetyinstructions and ware safety protections as gloves, goggle, helmet, safety boots, earprotectors.

WARNING: Before any operation stabilize and fix steadily all the elements on suitablepedestals. Stop the power packs, switch the general power breaker. Place a tag or aboard to warn other members of the personnel that maintenance work on the machineis in progress.

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

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

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnelwith special training for the particular equipment. Always read the instructions carefullybefore starting any maintenance work.

CAUTION: Always use suitable tools and work in a clean place when dismantling andassembling hydraulic components. After removing cylinders the hydraulic inlet/outletports must be plugged to prevent dirt and air intrusion during operation.

WARNING: The operator must always wear required personal protection, such as safetyhelmet, protective overall, safety boots, hearing protectors, safety goggles etc.

WARNING: 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)

Remember: SAFETY FIRST! Always observe the warnings accompanied by the following symbols.

WARNING

WARNING

WARNING

WARNING

WARNING





WARNING: Danger of hot surface.Hot surface can cause serious injuries.Components rod, shank or hydraulic component can be hot and beforestarting a maintenance work, please let them cool off.The operator must have adequate wears as gloves.

WARNING: Crushing hazard : do not stay in dangerous area, for instance: centralarticulation, front chassis and rear chassis.

WARNING

SAFETY

Do not attempt any such repairs or adjustments that you do not fullyunderstand.

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.

Make sure then that:

- 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.

Use proper tools.

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

Always follow the marked safety instructions, andobserve caution while working.

The following safety instructions are general rules.

Keep tools and drillingequipment clean.





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.





2 MAIN COMPONENTS

1 - ROTARY ACTUATOR HOUSING 7 - RADIAL BEARING

2 - SHAFT (2’ MOUNTING FLANGE, 2’’ BEARING TUBE 8 - LARGE RADIAL BEARING

3 - PISTON SLEEVE 9 - THRUST RING4 - PISTON 10 - GREASE NIPPLE

5 - END CAP 11 - SAFETY HYDRAULIC VALVE

6 - END CAP ALLEN SCREW

E2

E1

2’

9

8

2’’

2

1

4

3

7

9

6

5

10

10

11

10





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.

E2

E1

9

8

2

1

4

3

7

9

6

5





4 DISASSEMBLY

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

Remove the safety

hydraulic valves (11) and the

grease nipples (10).

• Remove the screws (6).

• Remove the cap (7).

• Unscrew the end cap (5).

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.

N

23

(Viewed from the mounting flange)





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

weld damage to the pins (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.

13

12





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.

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

• Install new bearing (15) on piston.

• Install new bearing and new seals on end

cap (4).

NOTE: the lip of exclusion seal (16) must be

directed outward, the lip of high pressure

seals (17) inward.

• 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 pressureseals (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.

14

15

4

3

5

17

17

16





6/2 PISTON

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.

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).

END CAP SIDE

SHAFT SIDE

1

4





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.

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




SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCE

s05 rotary actuator 360°

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