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L20 Series: Service and Repair Manual
L20 Series: Service and Repair Manual
L20 SERIES
Service and
Repair Manual
HA L20SM/04.16
INTRODUCTION
Table of Contents
Introduction
Table of Contents...................................................................................................................................................... 2
Product Introduction................................................................................................................................................. 3
General Safety Guidelines........................................................................................................................................ 3
Product Identification................................................................................................................................................ 4
Operation Technology............................................................................................................................................... 5
Tools
Tools Required.......................................................................................................................................................... 6
Drawings
Spare Parts............................................................................................................................................................... 7
Assembly Drawing.................................................................................................................................................... 8
Exploded View.......................................................................................................................................................... 9
Parts List................................................................................................................................................................... 10
Disassembly
Before Disassembly.................................................................................................................................................. 11
Disassembly............................................................................................................................................................. 11
Inspection................................................................................................................................................................. 16
Assembly
Assembly ................................................................................................................................................................. 17
Post Assembly
Grease Thrust Washers............................................................................................................................................ 22
Testing the Actuator.................................................................................................................................................. 23
Installation and Bleeding.......................................................................................................................................... 24
Troubleshooting Guide ............................................................................................................................................ 25
Warranty Information................................................................................................................................................ 26
2
INTRODUCTION
Product Introduction
3
INTRODUCTION
Product Identification
Each Helac actuator is individually serial num- Typical sample tag locations are seen below.
bered. The serial number is a five or six digit Note that the model number may begin with
number and must be provided before parts and/or either "HP" or "L20".
service issues can be addressed. Additionally, the serial number of the actuator is
The serial number can be found on the Identifica- stamped onto the side plate or the housing tube.
tion (ID) Tag that is affixed to all actuators. The It may be necessary to remove paint to expose
tag is a thin, silver colored, plastic material with the serial number.
a self-adhesive backing. Information is imprinted If the ID tag is not attached to the actuator and/or
in black. The tag is located either on the side the stamped serial number cannot be located,
plate or on the housing tube of the actuator. In the basic actuator model can be identified by
some cases, the ID tag may be painted over by measuring the outer diameter of the drilled and
the OEM (Original Equipment Manufacturer). tapped shaft flange.
Model Flange Diameter
L20-4.5 4.10” (104.14 mm)
L20-8.2 4.60” (116.84 mm)
L20-15 5.60” (142.24 mm)
L20-25 6.70” (170.18 mm)
L20-30 7.20” (182.88 mm)
L20-39 7.70” (195.58 mm)
4
INTRODUCTION
Operation Technology
The L20 Series rotary actuator is a simple mech- The shaft is supported radially by the large upper
anism that uses Helac's sliding spline technology radial bearing and the lower radial bearing (see
which converts axial piston motion into powerful drawings on pages 8 and 9). Axially, the shaft
shaft rotation. As seen in the illustration below is separated from the housing by the upper and
left, each actuator is composed of a housing with lower thrust washers. The end cap is adjusted
an integral ring gear (1) and only two moving for axial clearance and locked in position by set
parts: the central shaft (2), and the annular piston screws or pins.
sleeve (3). Note the L20 actuator shaft features
an integral mounting flange and bearing which The L20 Series is available in several different
are not shown in the illustration. sizes. All L20 Series actuators have the same
internal design and basic components, though
Helical spline teeth machined on the shaft en- configurations of parts may be slightly different
gage matching splines on the inside diameter depending on model.
of the piston. The outside diameter of the pis-
ton carries a second set of splines, of opposite Many L20 actuators are equipped with factory
hand, which engage the matching splines of the installed counterbalance valves, which perform
housing's ring gear. four major functions.
• Protects the actuator in the event of overload
As hydraulic pressure is applied, the piston is
displaced axially within the housing - similar • Enables the actuator to hold position without
to the operation of a hydraulic cylinder - while, drifting when external loads are applied
simultaneously, the splines cause the shaft to • Reduces hydraulic backlash by pressuring
rotate. When the control valve is closed, oil is the hydraulic fluid
trapped inside the housing, preventing piston • Provides a constant controlled rate of rotation
movement and locking the shaft firmly in position. in over-center load conditions
Bars indicate starting positions of piston Applying fluid pressure will displace the
and shaft. Arrows indicate direction they piston axially while the helical gearing causes
will rotate. The housing with integral ring the piston and shaft to rotate simultaneously.
gear remains stationary. For clarity, the The double helix design compounds rotation:
shaft flange, bearings, and end cap are not shaft rotation is about twice that of the piston.
shown. Applying pressure to the opposite port will
return the piston and shaft to their original
starting positions.
5
TOOLS
Tools Required
2. 4.
3.
1.
5.
12.
13.
11.
6. 8.
7.
16.
14. 15.
9. 10.
Several basic tools are required for the 14. SEAL TOOLS
disassembly and reassembly of the actuator. The Removal and installation of seals and wear
tools and their intended functions are outlined guides. Directions on making a seal tool are
below: provided at bottom.
1. PIPE VISE 15. PUNCH
2. TORQUE WRENCH 16. DOWEL PINS
Removal and replacement of port plugs and Removal and installation of end cap.
set screws.
3. ASSORTED SCREWS
4. SAFETY GLASSES
MAKING A SEAL TOOL
5. END CAP REMOVAL TOOLS (provided with
Helac seal kit). The seal tool is merely a customized stan-
dard flat head screwdriver.
6. DRILL
1. Heat the flat end with a torch until it
7. FLASHLIGHT glows.
Helps in locating and examining timing marks,
2. Secure the heated end of the screw-
component failure and overall condition.
driver in a vise and bend the heated end
8. RUBBER MALLET to a slight radius.
Removal and installation of shaft and piston 3. Round off all sharp edges of the heated
sleeve assembly. end to a polished finish. The tool may be
9. PLASTIC MANDREL modified slightly to your own personal
preference.
10. PRY BAR
Removal of end cap and manual rotation
of shaft.
11. FELT MARKER
Highlights timing marks and outlines troubled
areas. Permanent ink is recommended.
12. T-HANDLE SCREW EXTRACTOR
13. HEX WRENCH SET
Removal and replacement of port plugs and
set screws (106,113).
6
DRAWINGS
Spare Parts
Spare parts must be ordered through the vehicle/ Identification section on page 4. To identify spare
machine OEM. Seals and bearings are available parts required, refer to the Assembly Drawing on
as complete kits only. In order to obtain the correct page 8 and Parts List on page 10.
parts, it is essential to provide the serial num-
ber of the actuator to be repaired, see Product
Spare Parts
Technical Support
Technical support is available from Helac Corporation, Monday through Friday 7 am to 4 pm
Pacific Standard Time by calling 800-327-2589. If possible, please have the serial number of the
actuator available. (The serial number is stamped into the housing of the actuator-see page 4).
7
DRAWINGS
Assembly Drawing
01 A
420.2
202
200
400
02 204 207
421
421
04
205
206 206
401
VIEW A-A
90°
8
DRAWINGS
Exploded View
03
202
200
302
205
304
206
02
113
2
421 420
106
01
421
113
401 4
109
2
04
206
304
205
302
207
204
Template Rev J - T.U.
9
DRAWINGS
Parts List
Spare Parts
Spare parts must be ordered through the vehicle/machine OEM. Seals and bearings are available as complete kits
only. In order to obtain the correct parts, it is essential to provide the serial number for the actuator to be repaired.
See Product Identification on Page 4. To identify spare parts required, refer to the Assembly Drawing, Exploded View
Drawing and the Parts List.
Parts Seals
ITEM DESCRIPTION QUANTITY ITEM DESCRIPTION QUANTITY
01 HOUSING 1 200 T-SEAL 1
02 SHAFT 1 202 T-SEAL 1
03 PISTON SLEEVE 1 204 O-RING 1
04 END CAP 1 205 CUP SEAL 2
207 BACK-UP RING 1
Hardware 206 EXCLUSION SEAL 2
ITEM DESCRIPTION QUANTITY
103 SEALING SCREW (OPTIONAL) 2 Bearings
106 PORT PLUG 2 ITEM DESCRIPTION QUANTITY
109 LOCK PIN 2 302 WEAR GUIDE 2
113 CAP SCREW 6 304 THRUST WASHER 2
Accessories
ITEM DESCRIPTION QUANTITY
HYDRAULIC FLUID: ISO-VG-46 400 STOP TUBE (OPTIONAL) 1
401 COUNTERBALANCE VALVE (OPTIONAL) 1
403 MOTION CONTROL VALVE (OPTIONAL) 1
420 BUSHINGS (OPTIONAL) 2-4
421 BUSHINGS (OPTIONAL) 2
10
DISASSEMBLY
Before Disassembly
Before Disassembly
All numbers that appear
in parenthesis ( ) refer
to items in parts list on
page 10.
Disassembly
To avoid contamination
to machined parts:
Make sure work area is clean.
11
DISASSEMBLY
Disassembly
4. Remove the lock pins using a screw 7. Remove the end cap (04) and carefully
extracting tool such as an Easy OutTM (a set aside for later inspection.
size #2 is shown).
12
DISASSEMBLY
Disassembly
9. Every actuator has two sets of small 10. Prior to removing the shaft (02), use a
punched timing marks that indicate timing felt marker to clearly indicate the timing
between the gear sets. The location and between shaft and piston sleeve (03).
appearance of the marks can vary slightly This will greatly simplify timing when the
between models. One set indicates the actuator is reassembled.
timing between the piston sleeve (03) and
the housing (01) (photo at left), the sec-
ond set between the piston and the shaft
(lower photo). To ensure correct rotation
and accurate end positions, it is essential
that the actuator be correctly timed when
it is reassembled. The punched timing
marks can be used, but it is easier to
highlight punched marks with a marker
before disassembly as outlined in the
steps below.
13
DISASSEMBLY
Disassembly
13. To remove the piston (03) use a rubber 16. Remove the wear guide (302) from the
mallet and a plastic mandrel so the piston end cap (04) and shaft (02).
and housing bore are not damaged.
14
DISASSEMBLY
Disassembly
15
DISASSEMBLY
Inspection
16
ASSEMBLY
Assembly
Spraying fluids.
Contents under pressure.
Wear approved eye protection.
Use caution when removing
port plugs and fittings.
17
ASSEMBLY
Assembly
4. Using a seal tool (see Tools Required on 7. Install the inner T-seal (200) into the
page 6) install the main pressure seal appropriate groove in the piston (03).
(205) onto shaft (02) and end cap (04). Use a circular motion to insure the seal is
Use the seal tool in a circular motion. correctly seated in the groove.
Install the outer T-seal (202) by stretching
it around the groove in a circular motion.
Each T-seal has 2 back-up rings (see
Assembly Drawing on page 8 for
orientation).
Beginning with the inner seal (200)
insert one end of backup ring in the
lower groove and feed the rest in using
a circular motion. Make sure the wedged
5. Install the wear guide (302) on the end ends overlap correctly.
cap (04) and shaft (02).
Insert the other back up ring in upper
groove.
18
ASSEMBLY
Assembly
8. Insert the piston (03) into the housing (01) 10. Looking into the bore from the opposite
as shown, until the outer piston seal (202) end of the housing (01) be sure the timing
contacts the inside housing bore. marks align correctly. Rotate the piston
as necessary until aligned, then gently
tap the piston (03) into the housing until
the gear teeth mesh together. Tap the
piston into the housing until it completely
bottoms out against the ring gear.
19
ASSEMBLY
Assembly
12. Looking at the actuator from the end 14. Install the stop tube (400) onto the shaft
opposite the shaft flange, use the existing end if necessary. Stop tubes are an
timing marks to align the gear teeth on available option to limit the rotation of an
the shaft (02) with the gear teeth on the actuator.
inside of the piston (03). When the marks
align, gently tap the flange end of the
shaft with a rubber mallet until the gear
teeth engage.
20
ASSEMBLY
Assembly
21
POST ASSEMBLY
Greasing Thrust Washers
22
POST ASSEMBLY
Testing the Actuator
23
POST ASSEMBLY
Installation and Bleeding
TYPICAL CONFIGURATION OF
Avoid personal injury and
machinery damage: To avoid injury or damage ACTUATOR USED FOR WORK
Read the Service and Repair Manual
for proper installation, maintenance
to product: PLATFORM ROTATION
and repair procedures. Secure product to slotted table or vise.
Spraying fluids.
Contents under pressure. To avoid contamination
Wear approved eye protection.
Use caution when removing
to machined parts:
port plugs and fittings. Make sure work area is clean.
1. Connect a 3/16” inside diameter x 5/16” 3. Keep the fittings open and rotate the plat-
outside diameter x 5 foot clear, vinyl drain form in the opposite direction to the end
tube to each of the two bleed nipples. position. Maintain hydraulic pressure until
Secure them with hose clamps. Place the an additional ½ gallon of fluid is pumped
vinyl tubes in a clean 5-gallon container into the container.
to collect the purged oil. The oil can
be returned to the reservoir after this 4. Repeat steps 2 & 3. After the last ½ gallon
procedure is completed. is purged, close both bleed nipples before
rotating away from the end position.
24
POST ASSEMBLY
Troubleshooting Guide
CAUSE SOLUTION
1. Insufficient torque output Verify correct operating pressure. Do not exceed
OEM's pressure specifications. Load may be above
maximum capacity of the actuator.
2. Low rate of fluid flow Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.
3. Control or Counterbalance valve has Disconnect hydraulic lines and bypass valve. Leave
internal leak valve ports open and operate the actuator through
housing ports (do not exceed OEM's operating
pressure). The valve must be replaced if a steady flow
of fluid is seen coming from the valve ports.
4. Piston and/or shaft seal leak Remove the plug and the housing's valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in the
Testing Section on page 24 of this manual.
5. Corrosion build-up on the thrust surfaces Re-build the actuator. Remove all rust and then polish.*
6. Swollen seals and composite bearings Re-build the actuator. Use fluid that is compatible with
caused by incompatible hydraulic fluid seals and bearings. Contact Helac for more information
(Standard actuators only)
7. Air in actuator Purge air from actuator. See bleeding procedure
starting on page 24.
8. Twisted or chipped gear teeth from Check for binding. Actuator may or may not be able to
overload conditions. be rebuilt and may need to be replaced.
9. Port fittings are obstructing the piston Check thread length of port fittings. Fittings should
during stroke not reach inside the housing bore.
25
WARRANTY
Warranty Information
The warranty period shall be 12 months from the date of shipment from Helac Corporation’s manufacturing facility for
Helac Corporation approved applications. This warranty shall be voided as to any products which have been repaired,
worked upon, or altered by persons not authorized by Helac Corporation, or which have been subject to misuse,
negligence, accident, or overload. In no event shall Helac Corporation be liable for any incidental or consequential
damages.
Helac Corporation reserves the right to make changes in the design or construction of any of its products at any time
without incurring any obligations to make changes or alterations to products previously sold.
This warranty is in lieu of all other and/or prior warranties, expressed or implied, and no other company or person is
authorized to represent or assume for Helac Corporation any liability in connection with the sale of Helac Corporation
products other than set forth herein.
Upon receipt of the actuator(s) at the Helac Corporation facilities, an inspection will be performed and an authorized
representative will provide a written quote. This quote will list the findings of the inspection and will state whether or
not the warranty claim has been accepted. Actuators returned for credit may be subject to the Helac Corporation re-
stocking fee.
If Helac Corporation does not receive a response to their quote within 30 calendar days, the actuator will be either
scrapped or returned and an invoice for the debit amount, including the freight charges, will be sent to the claim
originator.
Prior to any returns, Return Material Authorization (RMA) form is to be requested from an authorized Helac
Corporation representative. Upon receipt of the RMA form, the customer is to provide part number, receipt date,
description of problem and the customer claim number. All shipments to Helac Corporation are to include the
completed RMA form.
26
Notes
27
© 2016 Helac Corporation. All rights reserved.
HELAC CORPORATION
®
225 BATTERSBY AVENUE • ENUMCLAW, WA 98022 USA
PHONE 360.825.1601 • FAX 360.825.1603 • www.helac.com