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ROTARY ACTUATOR

MAINTENANCE MANUAL

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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ROTARY ACTUATOR

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PRELIMINARY REMARKS

1/1

SAFETY

1/2

ABOUT THIS BOOKLET

MAIN COMPONENTS

ROTARY ACTUATOR : EXPLANATION

DISASSEMBLY

INSPECTION

5/1

HOUSING

5/2

SHAFT

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

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

A 06-2004 AR-MC-FL

ROTARY ACTUATOR

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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.
WARNING 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.
WARNING: 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 and ware safety protections as gloves, goggle, helmet, safety boots, ear
protectors.
WARNING: 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
WARNING is in progress.
WARNING: 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.
WARNING
NEVER WORK ON AN OPERATING CIRCUIT.
WARNING: 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.
WARNING

WARNING: 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.
WARNING

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

WARNING

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

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ROTARY ACTUATOR

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WARNING: 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.
The operator must have adequate wears as gloves.
WARNING: Crushing hazard : do not stay in dangerous area, for instance: central
articulation, front chassis and rear chassis.
WARNING

SAFETY

Always follow the

marked safety instructions, and
observe caution while working.
The following safety instructions are general rules.
Keep tools and drilling
equipment clean.

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

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, and
other safety equipment required by the work.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

ROTARY ACTUATOR

A 06-2004 AR-MC-FL

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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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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ROTARY ACTUATOR

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2 MAIN COMPONENTS

10

10

E2
4
3

E1

10

1
8
9

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 BEARING
9 - THRUST RING
10 - GREASE NIPPLE
11 - SAFETY HYDRAULIC VALVE

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

A 06-2004 AR-MC-FL

ROTARY ACTUATOR

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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.

2
5

E2
4
3

E1
1
8
9

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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4 DISASSEMBLY

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

N
3
2

Remove the safety

hydraulic valves (11) and the
grease nipples (10).
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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

ROTARY ACTUATOR

A 06-2004 AR-MC-FL

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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

12
13

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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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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
14

install seals (14) in piston sleeve and piston.

Install new bearing (15) on piston.

4
3

16

Install new bearing and new seals on end

cap (4).

17

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
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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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ROTARY ACTUATOR

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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.

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).

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

ROTARY ACTUATOR

A 06-2004 AR-MC-FL

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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 Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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ROTARY ACTUATOR

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

A 06-2004 AR-MC-FL