HELICAL HYDRAULIC ROTARY ACTUATORS

T20 SERIES
Service and
Repair Manual
INTRODUCTION
Table of Contents
Introduction
Table of Contents ......................................................................................................................................................................... 2
Product Overview ........................................................................................................................................................................ 3
Operation Technology .................................................................................................................................................................. 4
General Safety Guidelines ............................................................................................................................................................ 5
Product Identification .................................................................................................................................................................. 6

Maintenance and Troubleshooting

Maintenance ................................................................................................................................................................................ 7
Troubleshooting Guide................................................................................................................................................................. 8

Tools
Tools Required ............................................................................................................................................................................ 9

Drawings
Assembly Drawings ..................................................................................................................................................................... 10
Exploded Views ........................................................................................................................................................................... 12
Exploded View - Valve Block ........................................................................................................................................................ 14
Parts List - Valve Block ................................................................................................................................................................ 14
Parts List ..................................................................................................................................................................................... 15

Disassembly
Component Identification ............................................................................................................................................................ 16
Product Inspection ...................................................................................................................................................................... 17
End Cap and Bearing Removal ..................................................................................................................................................... 17
Shaft Removal ............................................................................................................................................................................. 20
Piston Sleeve Removal ................................................................................................................................................................ 21
Seal Removal ............................................................................................................................................................................... 22
Component Inspection................................................................................................................................................................. 23
Timing Mark Inspection ............................................................................................................................................................... 23

Assembly
Dry Assembly .............................................................................................................................................................................. 24
Seal Installation ........................................................................................................................................................................... 24
Piston Sleeve Installation ............................................................................................................................................................. 26
Shaft Installation.......................................................................................................................................................................... 27
End Cap and Bearing Installation ................................................................................................................................................. 27

Post Assembly
Testing the Actuator ..................................................................................................................................................................... 29
Bleeding the Actuator .................................................................................................................................................................. 30
Warranty Information ................................................................................................................................................................. 31
Service Offering .......................................................................................................................................................................... 32
About Helac Corporation.............................................................................................................................................................. 36

2
INTRODUCTION
Product Overview

Product Introduction

NOTICE Content in this Service and Repair The T20 Series rotary actuators feature a one-
Manual applies to all current T20 piece through shaft and internal tapered roller
Series product models — unless bearings and are commonly used for applications
otherwise noted. For information where torque generation and higher frequency
on maintaining, servicing or cycling are the primary requirements. The T20
repairing earlier HS Series Series can carry substantial radial, thrust and
actuators — please contact moment loads without external bearings while, at
Helac Corporation's Service the same time, facilitating smooth operation and
Department at +1 800 327 2589 low breakaway pressures.
(U.S. and Canada) or
+1 360 825 1601 (Worldwide). The T20 Series is available in three different sizes
with torque outputs ranging from 25,000 - 60,000
NOTICE We have used the T20-25 model in-lbs at 3,000 psi.
actuator as a baseline throughout
the manual. Variations in the
T20-45 and T20-60 models will
be noted where applicable.

3
INTRODUCTION
Operation Technology

The T20 Series rotary actuators use Helac Helical spline teeth on the shaft engage matching
Corporation’s innovative, sliding-spline operating teeth on the piston’s inside diameter. A second set
technology to convert linear piston motion of splines on the piston’s outside diameter mesh
into powerful shaft rotation. Each actuator is with the gear in the housing.
composed of a housing and two moving parts
— the central shaft and piston.

Starting Position

The piston is completely bottomed out.

Bars indicate starting positions of piston
and shaft. Arrows indicate directions they
will rotate. The housing with integral ring
gear remains stationary.

Ending Position

When hydraulic pressure is applied to the

piston, it moves axially while the helical
gearing causes the piston and shaft to rotate
simultaneously. Applying pressure to the
opposite port will return the piston and shaft
to their original starting positions.

4
INTRODUCTION
General Safety Guidelines

Cautionary Notices Important Notice

Before beginning service and/or repair of the T20 Helac Corporation does not assume any
Series rotary actuator, there are several cautionary responsibility beyond the design and performance
notices that should be considered. If you are not of its rotary actuator product. The customer is
comfortable with repair or maintenance of this solely responsible for engineering of mating
product, contact Helac Corporation's Service structures, fasteners, and other associated
Department for assistance. components related to the installation of the
product and its ultimate application.

Due to the unlimited variety of operating conditions

and applications, Helac Corporation does
not certify any application unless specifically
requested to do so by the customer. The overall
integrity of the installation, and the application’s
safety and compliance with industry standards
and warning requirements are the ultimate
responsibility of the customer. Helac Corporation
recommends that prototype testing be conducted
to verify installation integrity. Testing with applied
loads that equal or exceed the static and dynamic
load frequency and intensity are recommended
to determine the suitability of the actuator for the
application.

Secure product to work bench. To prevent misapplication of our products and

to assure the most appropriate actuator is used
for the application under consideration, a Helac
Corporation questionnaire is available so that
installation details can be evaluated.

WARNING
IMPROPER SELECTION, INSTALLATION OR USE OF HELAC
PRODUCTS OR SYSTEMS MAY RESULT IN FAILURE AND CAUSE
DEATH, PERSONAL INJURY OR PROPERTY DAMAGE.

Documents or information provided by Helac Corporation,

its subsidiaries or authorized distributors are intended for
users having technical expertise. It is important to thoroughly
analyze all aspects of your application and review current
product information. The user is solely responsible for the final
selection of any Helac Corporation product or system and its
suitability for the application in question.

5
INTRODUCTION
Product Identification

A unique serial number is located on each T20

Series rotary actuator. The serial number is
stamped on the housing and can also be found on
the Identification (ID) Tag. The serial number may
be required before parts and/or service issues can
be resolved. In some cases, it may be necessary
to remove paint to expose the serial number.

6
MAINTENANCE AND TROUBLESHOOTING
Maintenance

Daily Weekly
1. Apply a clean lithium or compatible grease to 1. Apply a clean lithium or compatible grease
the grease fittings daily when operating the to the grease fittings weekly when operating
actuator in severe conditions such as abrasive the actuator in non-severe environments and
dust or prolonged submersion in water. conditions. Apply grease until grease flows
Apply grease until grease flows from the from the grease reliefs.
grease reliefs or shaft exclusion seal.
2. Make sure the grease reliefs are functioning
2. Make sure the grease reliefs are functioning properly. Open or replace non-functioning
properly. Open or replace non-functioning grease reliefs immediately.
grease reliefs immediately.

NOTICE Never replace the grease relief

valves with grease fittings or
plugs.
NOTICE Do not operate the actuator if the
grease reliefs are not functioning.
NOTICE Helac Corporation uses a lithium-
based grease in assembly. A high
quality grease compatible with
lithium grease may be used.
NOTICE The T20-25 and T20-45 are
greased through the grease zerks
on the spline adapters.

The T20-60 is greased through

the grease zerks on the housing
and grease relief fittings on the
end cap.

7
MAINTENANCE AND TROUBLESHOOTING
Troubleshooting Guide

Problem Possible Cause Solution

Shaft rotates slowly or not at all Insufficient torque output Verify correct operating pressure.
Do not exceed OEM’s pressure
specifications. Load may be above
maximum capacity of the actuator.

Low rate of fluid flow Inspect ports for obstructions and

hydraulic lines for restrictions and leaks.

Counterbalance valve has internal leak Disconnect hydraulic lines and bypass
valve. Leave 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.

Leak in piston and/or shaft seal Remove the port plugs 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 29.

Corrosion build-up on the Re-build the actuator. Remove all rust,

thrust surfaces clean thoroughly and then polish.*

Swollen seals caused by incompatible Re-build the actuator. Use fluid that is
hydraulic fluid (standard actuators only) compatible with seals and bearings.
Contact Helac Corporation for
more information.

Air in actuator Purge air from actuator. See bleeding

procedures outlined on Page 30.

Operation is erratic or not responsive Air in actuator Purge air from actuator. See bleeding
procedures outlined on Page 30.

Selected position cannot be maintained Counterbalance valve has internal leak Disconnect hydraulic lines and bypass
valve. Leave 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.

Leak in piston and/or shaft seal Remove the port plugs 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 29.

Air in actuator Purge air from actuator. See bleeding

procedures outlined on Page 30.

* Replacement parts may be needed.

8
TOOLS
Tools Required

12.
5.

7. 10.
6.
11.
3.
9.
1. 4. 8.

2.

Several basic tools are required for the

disassembly and reassembly of the actuator. Making a Seal Tool
The suggested tools are outlined below:
The seal tool is merely a customized standard
1. Plastic mandrel flat head screwdriver.
2. Pry bar
1. Heat the flat end with a torch until it glows.
3. Plastic or rubber mallet
2. Secure the heated end of the screwdriver
4. Flashlight in a vise and bend the heated end to a
5. Hex wrenches slight radius.

6. Felt marker 3. Round off all sharp edges of the tip to a

polished finish. The tool may be modified
7. Socket wrench slightly to your own personal preference.
8. Seal tool
9. Dowel pins
10. Needle nose plier
11. Brush
12. Safety glasses

NOTICE All fasteners are english.

9
DRAWINGS
T20-25 and T20-45 Assembly Drawing

10
DRAWINGS
T20-60 Assembly Drawing

11
DRAWINGS
T20-25 and T20-45 Exploded View

12
DRAWINGS
T20-60 Exploded View

13
DRAWINGS
Exploded View — Valve Block

Valve Port
ISO 11926-1
7/16-20 (SAE-4)
or BSPP G 1/4
ISO 1179

Parts List — Valve Block

PARTS
Item Description Quantity

A ............. Seal Kit — Valve Cartridges ........................1

B ............. Relief Manifold .............................................1
C ............. Counterbalance/Relief Valve .......................2
D ............. Seal O-Ring .................................................2

14
TOOLS
Parts List — Actuator

PARTS
Item Description Quantity Order Your Spare and
Replacement Parts Today
01 ........... Housing ......................................................1
02 ........... Shaft ...........................................................1 Spare or replacement parts can be ordered
03 ........... Piston Sleeve .............................................1 online at www.helac.com/service/parts.asp
04 ........... End Cap .....................................................2
or by calling Helac Corporation’s Service
07............ T20-60 Adapter ...........................................2
Department at +1 800 327 2589 (U.S. and
09............ T20-60 Spacer ............................................2
Canada) or +1 360 825 1601 (Worldwide),
Monday through Friday, 7 a.m. to 4 p.m. PST.
HARDWARE
Item Description Quantity When ordering Spare and Replacement Parts,
including Seal and Bearing Kits, please have
102 ......... Screw .........................................................2
the serial and/or model number available.
106 ......... Plug Fitting (SAE-4 or SAE-6) ....................4
106.2 ...... SAE-4 Plug Fitting ......................................2
These reference numbers are located on the
107 ......... Cup Bearing ...............................................2 ID Tag as noted on Page 6.
108 ......... Cone Bearing .............................................2
109 ......... Dowel Pin ...................................................2
111 ......... Grease Fitting .............................................2
112 .......... T20-60 Grease Relief Valve........................2
113 ......... Spacer ........................................................2

SEALS
Item Description Quantity

200 ......... Cup Seal — Piston Sleeve .........................1

201 ......... Cup Seal — Piston Sleeve .........................1
202 ......... Cup Seal — Piston Sleeve .........................1
203 ......... Cup Seal — Piston Sleeve .........................1
204 ......... O-Ring Seal — End Cap ............................2
205 ......... Cup Seal — Shaft ......................................2
206 ......... Wiper Seal — End Cap ..............................2
204 ......... O-Ring Seal — End Cap ............................2
208 ......... O-Ring Seal — Spline Adapter ..................2
209.1 ...... O-Ring Seal — End Cap ............................2
209.2 ...... B/U Ring Seal — End Cap .........................2
301.......... T20-60 Dura Comp Bearings* ....................1

* Used on T20-60 units only

15
DISASSEMBLY
Component Identification

3.

5.

4. 1.

2.

CAUTION
NOTICE All numbers that appear in
parenthesis ( ) in the following
Spraying fluids:
Contents under pressure.
sections refer to items on
Wear approved eye protection. Page 15.
Use caution when removing
port plugs and fittings.
The T20 helical, hydraulic rotary actuator is
comprised of the following components:

1. Housing
2. Shaft
Secure product to work bench.
3. Piston Sleeve
4. End Caps
5. Bearings

16
DISASSEMBLY
Product Inspection

Make sure the T20 is thoroughly cleaned prior to Severe corrosion can make it difficult to remove
disassembly. Continue to clean all machined parts the dowel pins (109) or set screws and to unthread
in a wash tank and dry with compressed air. Be the end cap (04). If corrosion is evident, soak the
sure to inspect the actuator prior to disassembly. pins or screws for several hours with penetrating
oil before attempting to disassemble the actuator.

End Cap and Bearing Removal

Be sure actuator has been fully rotated clockwise 4. Use the needle nose plier to remove the dowel
from Port P1 and the actuator housing is firmly pin that locks the end cap.
secured to a work bench.

1. Carefully remove the four plug fittings

(106). Drain the hydraulic oil and inspect for
contamination (i.e., dirt, water and metal).

NOTICE The T20-60 end cap is locked with

a dowel pin and closed with a
SAE 4 plug, 90° from mounting
plane, in line with ports and
grease zerk — one on each end.
2. On models equipped with grease relief fittings
5. On models equipped with grease zerk fittings,
(112), remove them from each end cap (04).
(111) remove them from each end of the
3. Remove the SAE 4 fitting plug (106.2) to housing.
access the end cap locking device, the dowel
6. To simplify re-assembly, mark the position of
pin (109).
the end caps (04) in relation to the housing
(01).

17
DISASSEMBLY
End Cap and Bearing Removal

7. Unscrew both end caps (04) using dowel pins 9. Remove the bearing (108). Take note of which
or bolts placed opposite each other in the end the bearings are removed, so they can
spanner holes. Turn counterclockwise with a be paired with the same bearing race during
pry bar. Slide end caps off. re-assembly.

T20-60 Bearing Removal

The T20-60 bearings are press off bearings
and require special care during removal. We
recommend utilizing a ram and bearing splitter to
remove the T20-60 bearings.

1. Align ram with port P2 end of shaft.

8. Remove the seal (205) and spacer (113).

2. Depress ram to force shaft downward to

release the bearing.

18
DISASSEMBLY
End Cap and Bearing Removal

2. Depress ram to force shaft downward to 6. Remove bearing from the shaft.
release the bearing.

Check the condition of the bearings after the

3. Remove bearing from the shaft. Verify timing removal procedure, they may need to be replaced.
marks on the shaft.

4. Install bearing splitter and replace shaft in

the ram.

5. Depress ram to force shaft downward to

release the bearing.

19
DISASSEMBLY
Shaft Removal

1. Look inside the housing (01), locate the gear 2. Slowly remove the shaft (02) from the piston
teeth end of the piston sleeve (03). Timing sleeve (03) by pulling and turning at the
marks (center punches) will be visible on the same time.
ring gear inside the housing (01), on the piston
sleeve (03) and on the shaft (02). Typically
there should be two marks close together on
the piston sleeve, one for inside and outside
gear teeth. The shaft timing marks could
also be in the valley between the teeth of the
gears. If no timing marks are located on any
items, use a push type center punch to make
new marks.
When timing marks are located, use either
punch or a permanent marker (may wash The T20-60 shaft is removed
NOTICE
off) to mark all the items. When doing re- during the bearing removal
assembly, these marks will need to be lined up procedure outlined in the
to achieve proper timing. previous section.

20
DISASSEMBLY
Piston Sleeve Removal

1. Before removing the piston sleeve (03) double 3. Place a mark on the housing (01), and on the
check the timing marks of the housing (01) in piston sleeve (03) in line with a port fitting or
relation to the piston sleeve (03). some other reference. This will simplify the
process of aligning the piston to the ring gear
teeth during re-assembly.

2. Slowly turn the piston sleeve (03) while using

a plastic hammer and mandrel to gently tap
the piston sleeve (03) to disengage the gear
teeth from the housing ring gear teeth inside
the housing bore.

21
DISASSEMBLY
Seal Removal

1. Remove shaft I.D. cup seal (205) and end cap 4. Remove the piston sleeve O.D. cup seals
O.D. O-ring seal (204) from the end cap (04). (202, 203) from the piston (03).
Watch for any signs of scratches or gouges
that could cause internal leaks or
premature wear.

5. Remove the piston sleeve I.D. cup seals

(200, 201) from the piston (03).

2. Remove end cap O.D. O-ring seal (209.1)

and B/U ring seal (209.2).

NOTICE The T20-45 does not include a

spacer ring. Instead it features a
complete seal groove.

The T20-60 features bronze

PTFE/HNBR cap seals on piston
and rod sides and a duracomp
3. Remove end cap I.D. wiper seal (206).
wear guide on the rod side of the
sleeve. The T20-60 also features
a Nitrile Z-seal for the end cap
pressure seal and a polyurethane
burp seal as the end cap
exclusion seal.

22
DISASSEMBLY
Component Inspection

1. Prior to inspection, clean all parts in a wash 4. End Caps

tank and dry with compressed air.
Inspect the threads for galling or cross
2. Housing threading. Make sure that the end cap spins
freely in the threads of the housing. Evaluate
Inspect the cylinder bore for wear and
the surface finish of the seal grooves.
scratches. Local polishing can repair minor
scratches and damage. Inspect all bearing and 5. Piston Sleeve
seal surfaces for signs of wear or damage.
Inspect the condition of the gear teeth.
Check the condition of the gear teeth for any
Evaluate the surface finish of the seal grooves.
signs of extreme wear or chipping. Inspect the
exterior of the housing for signs of damage or 6. Bearings
cracking.
Check bearings for cracks, damage and signs
3. Shaft of wear. Bearings showing wear or damage
should be replaced.
Check the shaft surface for scratches from the
piston seal or other damages. Small or minor 7. Seals
scratches can be carefully polished. Examine
the condition of the gear teeth. Helac recommends replacement of all seals.

Timing Mark Inspection

1. Locate the timing marks on the shaft (02),

piston sleeve assembly (03) and housing (01).
Re-mark with a permanent marker or paint
stick if needed.

23
ASSEMBLY
Dry Assembly

In some cases, for repair personnel not familiar This will provide a better idea of how to properly
with the actuator assembly process, it may be align the gear teeth. A "dry" assembly is typically
beneficial to perform a "dry" assembly. done without seals, yet requires bearing
installation.

Seal Installation

Pre-Assembly 2. Before installing seals, coat the seals and

machined surfaces with a clean hydraulic oil.
NOTICE Assembly procedures require the
housing to be firmly secured to the
work bench.

NOTICE Thoroughly clean all components

and lubricate all seals, bearings
and contact surfaces with
hydraulic oil prior to final
installation.
1. Gather all the components and tools into
one location prior to re-assembly. Use the 3. First, install the end cap O.D. B/U ring seal
drawings on Page 12 and 13 to reference the (209.2) to the end cap (04). Ensure the
seal orientations. concave side of the B/U seal faces the
O-Ring.

NOTICE The T20-45 does not include a

spacer ring. Instead it features a 4. Next, install the end cap O.D. O-ring seal
complete seal groove. (209.1) into the end cap (04). Seal (209.1) is
slightly smaller in diameter than (204).
The T20-60 features bronze
PTFE/HNBR cap seals on piston
and rod sides and a duracomp
wear guide on the rod side of the
sleeve. The T20-60 also features
a Nitrile Z-seal for the end cap
pressure seal and a polyurethane
burp seal as the end cap
exclusion seal.

24
ASSEMBLY
Seal Installation

5. Using hands or a seal tool install the 8. Install the piston sleeve O.D. cup seal (203)
end cap exclusion O-ring seal (204). Seal onto the piston sleeve (03). Make sure to
(204) is slightly larger than (209.1). remove the energizer from the cup seal to
prevent pressure trapping.

6. Install the end cap I.D. wiper seal (206)

into the end cap (04). 9. Install the piston sleeve O.D. cup seal (202)
onto the piston sleeve (03). (This seal should
still have the energizer in it.)

7. If needed remove the energizer (small O-ring)

from the inside the piston sleeve O.D. cup
seal (203) prior to installation. Also remove the 10. Remove the energizer from the piston sleeve
energizer from inside the piston sleeve I.D. I.D. cup seal (201) prior to installation. Install
cup seal (201). the piston sleeve I.D. cup seals (200) and
(201) inside the piston sleeve (03). (201)
should be closest to the gearing.

25
ASSEMBLY
Piston Sleeve Installation

1. Secure the actuator housing to a work bench. 4 . Use a rubber or plastic mallet and plastic drift
Coat the inside of the housing (01) with clean to engage the piston sleeve gear teeth and
hydraulic oil to reduce the chance of seal housing ring gear. Drive the piston sleeve in
damage. until the front of the piston sleeve (03) is lined
up with the timing marks on the housing (01)
2. Carefully slide the piston sleeve (03), gear ring gear.
teeth first, into the housing (01). Be careful not
to bind or jam the piston sleeve in the housing.
Refer to Pages 10-13 for piston orientation.

3. Confirm proper timing by aligning the piston

sleeve (03) timing marks with timing marks in
the housing (01). 5. Using a rubber or plastic mallet and a plastic
drift, continue to drive the piston sleeve (03)
towards the end of the actuator, until the
piston sleeve reaches the end of its travel.

26
ASSEMBLY
Shaft Installation

1. Before installing the shaft (02), coat the shaft 3. Verify the timing marks before fully rotating the
with clean hydraulic oil. shaft into the piston sleeve (03).
2. Insert the shaft (02) into the piston sleeve (03),
carefully aligning the timing marks on the shaft
with the piston. Take care not to damage the
piston seals with the spline end of the shaft.

End Cap and Bearing Installation

1. Coat the bearings (108) with clean hydraulic 2. Coat end cap (04) threads with anti-seize
oil and install on each end of the shaft (02) as grease.
noted during disassembly. If needed, use a
sleeve to press bearing onto shaft. Be careful
not to damage the shaft, seal surfaces or
splines during installation. Install spacer (113)
and seal (205) on each end of the shaft.

NOTICE It may be necessary to heat

T20-60 bearings to 200°
Fahrenheit prior to installing on
each end of the shaft for a slip fit.

27
ASSEMBLY
End Cap and Bearing Installation

3. Install end caps (04) one at a time. The first 5. On models equipped with set screws (105),
end cap installed must line up with the marks install them using Loctite 242. Firmly torque,
on the housing and dowel pin (109). Next and then back off one-quarter turn. On models
install the second end cap (04) and torque to equipped with the dowel pin (109) and port
200 ft. lbs. Loosen and re-torque end cap to plugs (106.2) install them into the
200 ft. lbs. If the locking pin (109) does not housing (01).
line up within one diameter of the hole, the
6. On models equipped with grease zerks and
holes must be re-drilled. If within one diameter,
reliefs, install them on the housing (01). Install
loosen end cap or tighten to align the holes.
grease relief valves on both end caps (04).
Both end caps should be very close to flush
with the end of the housing. 7. Shaft seals must then be filled with lubricating
grease. The grease provides lubrication,
prevents water condensation and minimizes
water ingress, which can corrode internal
surfaces. In order to maximize grease
distribution, the actuator should be connected
to the hydraulic system of the equipment or
a test bench and cycled slowly as grease is
applied. Apply grease slowly as the actuator is
rotating until grease flows from the relief valve.
Cycle the actuator and apply grease again.

4. For re-drilling actuators with dowel pins (109),

use a drill bushing to create a 0.188” diameter
hole. Drilled depth should match the dowel pin
hole on the opposite end. Do not drill deeper.

28
POST ASSEMBLY
Testing the Actuator

NOTICE The T20-25 and T20-45 are

greased through the grease zerks
on the spline adapters.

The T20-60 is greased through

the grease zerks on the housing
and grease relief fittings on the
end cap.
CAUTION
Spraying fluids:
Contents under pressure.
Wear approved eye protection.
Use caution when removing
port plugs and fittings.
Testing for Internal Leakage

1. Connect a 350 bar test gauge into the

hydraulic line to Port P1. Pressurize Port P1
until the shaft reaches the end of rotation.

Secure product to work bench.

NOTICE If the shaft is not completely
bottomed out, hydraulic fluid will
exhaust from Port P2 at a high
velocity.
2. Remove and cap the hydraulic line to Port
P2. Pressurize Port P1 to 175 bar. Check
for leakage at Port P2 and from around the
main shaft and end cap seals. Leaks indicate
improperly installed parts.
3. Reconnect the hydraulic line to Port P2 and
Testing and Greasing pressurize P2 as in Step 1 above.
4. Check for leaks at Port P1 and around the
Attach the actuator to either a hydraulic test bench main shaft and end cap seals as in Step 2
or portable pump for greasing and testing. Make above.
sure the actuator is secured to prevent movement.
If not in place, install the grease fittings and
grease reliefs.

1. After the actuator is assembled but before

it is put back into service, the shaft seals
must be packed with clean lithium or
compatible grease.
2. Locate the grease fittings or ports on the
actuator and using a grease gun, pack the
seals with grease until it exhausts from the
grease reliefs.
3. Cycle the actuator slowly and re-grease as
necessary. During testing, it is recommended
that the actuator be cycled 20 to 30 times to
remove air, check for leaks and the proper
degrees of rotation.

29
POST ASSEMBLY
Bleeding the Actuator

6. Apply pressure to port V1 until actuator has

fully rotated in the opposite direction.
7. With port P2 still venting to tank or 5 gallon
container, apply pressure to port V2 allowing
oil/air to be purged from the open port.
8. Install port P2 plug.
CAUTION
9. All air should be purged from the actuator.
Spraying fluids:
Contents under pressure.
Wear approved eye protection.
For actuator without optional valve
Use caution when removing block installed.
port plugs and fittings.

Air should be purged through the upper ports P1

and P2. With that in mind, apply pressure hoses
to the lower ports P1 and P2. See T20 Assembly
Drawing on Page 10 and 11 for port location.

1. Connect a hydraulic line to upper port P1

routed either back to tank or to a minimum 5
gallon container to collect the purged oil.
2. Apply pressure to lower port P2 until actuator
has fully rotated to one side.
3. With upper port P1 still venting to tank or 5
gallon container, apply pressure to the lower
port P1 allowing oil/air to be purged from the
After installation of the actuator onto the open port.
equipment, it is important that all safety devices 4. Install upper port P1 plug and attach purge
such as tie rods or safety cables be properly line to upper port P2.
reattached. The actuator body is equipped with a
pair of port plugs (106) which can be removed 5. Apply pressure to lower port P1 until actuator
for bleeding. has fully rotated to the opposite side.
6. With upper port P2 still venting to tank or 5
For actuator with an optional valve
gallon container, apply pressure to the lower
block installed.
port P2 allowing oil/air to be purged from the
1. Connect the pressure lines to ports V1 open port.
and V2. 7. Install upper port P2 plug.
2. Connect a hydraulic line to port P1 routed 8. All air should be purged from the actuator.
either back to tank or to a 5 gallon container to
collect the purged oil.
3. Apply pressure to port V2 until actuator has
fully rotated to one side.
4. With port P1 still venting to tank or 5 gallon
container, apply pressure to the primary port
V1 allowing oil/air to be purged from the
open port.
5. Install port P1 plug and attach purge line to
port P2.

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Warranty Information

Standard Warranty Information Return and Debit Policy for Actuators

Helac Corporation warrants its manufactured Unless agreed to in advance, all actuators
products to be free from defective material will be shipped to Helac Corporation, freight
and factory workmanship. Helac Corporation prepaid within seven days after receipt of return
shall replace or repair such products, which authorization. Prior to any returns, a Return
under normal use and service disclose such Material Authorization (RMA) form is to be
defects, and return the repaired or replacement requested from an authorized Helac Corporation
products to the purchaser prepaid. Claims under representative. Upon receipt of the RMA form, the
this warranty will be satisfied only by repair or customer is to provide when applicable, the part
replacement of the unit or any defective part number, serial number, failure date, description
thereof. No cash payment or credit will be made of problem and the customer claim or reference
for defective materials, workmanship, labor or number. All shipments to Helac Corporation are to
incidental charges. Products under warranty shall include the completed RMA form.
be returned to Helac Corporation’s manufacturing
facility at 225 Battersby Avenue, Enumclaw, Upon receipt of the actuator(s) at the Helac
Washington 98022 USA, transportation prepaid by Corporation facilities, an inspection will be
the purchaser, for inspection by Helac Corporation, performed and an authorized representative will
whose opinion as to defects shall be conclusive. provide a written quote. This quote will list the
findings of the inspection and will state whether
The warranty period shall be 12 months from or not the warranty claim has been accepted.
the date of shipment from Helac Corporation’s Actuators returned for credit may be subject to the
manufacturing facility for Helac Corporation Helac Corporation re-stocking fee.
approved applications. This warranty shall be
voided as to any products which have been If Helac Corporation does not receive a response
repaired, worked upon, or altered by persons not to their quote within 30 calendar days, the actuator
authorized by Helac Corporation, or which have will be either scrapped or returned and an invoice
been subject to misuse, negligence, accident, or for the debit amount, including the freight charges,
overload. In no event shall Helac Corporation be will be sent to the claim originator.
liable for any incidental or consequential damages. Return and Debit Policy for Service Parts
Helac Corporation reserves the right to make Return of service parts, normally stocked by Helac
changes in the design or construction of any of Corporation, must be authorized in advance. This
its products at any time without incurring any will include seal and bearing kits as well as any
obligations to make changes or alterations to and all fabricated parts. Return of any special
products previously sold. order parts will be authorized on a case-by-case
This warranty is in lieu of all other and/or prior basis. All returns are to be shipped to Helac
warranties, expressed or implied, and no other Corporation freight prepaid within seven days after
company or person is authorized to represent receipt of return authorization. Helac Corporation
or assume for Helac Corporation any liability in has a minimum re-stocking fee of 20 percent.
connection with the sale of Helac Corporation Prior to any returns, Return Material Authorization
products other than set forth herein. (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.

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POST ASSEMBLY
Service Offering

Helac Corporation’s Service Department can

Repair Service
effectively tackle your service and repair needs
and provide responsive customer support. Our Our fully equipped repair department ensures
30 years of extensive rotary actuator expertise factory specifications and customer expectations
coupled with an in-depth understanding of our are met quickly and efficiently.
customers’ expectations, enables us to quickly
and efficiently service your needs with the Call or e-mail our Repair Department at
following three offerings: +1 800 327 2589 (U.S. and Canada),
+1 360 825 1601 (Worldwide) or
Technical Support
Repairs@Helac.com.
Our service representatives have been trained to
answer the majority of your technical questions Parts Service
during the initial call. If your question can’t be Our parts service team offers same day or 24
answered immediately, our representative will hour turnaround, depending on when the call is
return your call quickly. received, on all common items.

Call our Technical Support Department at When ordering Spare and Replacement Parts,
+1 800 327 2589 (U.S. and Canada) or including Seal and Bearing Kits, please have the
+1 360 825 1601 (Worldwide) from 7 a.m. to 4 serial and model number available.
p.m. PST on weekdays (excluding holidays), or
e-mail us at TechSupport@Helac.com. Spare parts can be ordered online at
www.helac.com/service/parts.asp, or by calling
or e-mailing our Parts Department at
+1 800 327 2589 (U.S. and Canada),
+1 360 825 1601 (Worldwide) or
parts@helac.com

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 Notes

33
 Notes

34
 Notes

35
 About Helac Corporation

As a leader in the fluid power industry for over reliable performance. Helac PowerTilt and
30 years, Helac Corporation manufactures a PowerGrip, two specialty products, increase the
comprehensive line of hydraulic rotary actuators utilization of backhoes and excavators.
and construction equipment attachments. Over 1,000 worldwide customers in diverse
Helac rotary actuators are best known for their markets depend on Helac's product lines to
tremendous torque output, compact dimensions, provide product quality, reliability, ease of use
exceptional load bearing capability and rugged, and durability.

HELAC CORPORATION
225 BATTERSBY AVENUE • ENUMCLAW, WA 98022 USA
Rev 12-2007

36 ®
PHONE 360.825.1601 • FAX 360.825.1603 • www.helac.com