POWERTILT Instruction,Service and Repair Manual PT, PTA and PTB Series CONSTRUCTION EQUIPMENT ATTACHMENTS ®
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POWERTILTInstruction,Serviceand Repair Manual
PT, PTA and PTB Series
CONSTRUCTION EQUIPMENT ATTACHM
ENTS
®
2
Table of Contents
IntroductionTable of Contents .................................................................................................................................................... 2Product Overview .................................................................................................................................................... 3Operation Technology ............................................................................................................................................ 5General Safety Guidelines ...................................................................................................................................... 6Product Identification .............................................................................................................................................. 7
Installation and MaintenanceInstallation and Mounting ....................................................................................................................................... 8Hydraulic Requirements and Plumbing ................................................................................................................ 10Maintenance ......................................................................................................................................................... 13Trouble Shooting Guide ....................................................................................................................................... 14
ToolsTools Required ...................................................................................................................................................... 15
DrawingsAssembly Drawings .............................................................................................................................................. 16Piston Drawings .................................................................................................................................................... 20Exploded View ...................................................................................................................................................... 21Parts List ............................................................................................................................................................... 22
DisassemblyComponent Identification ...................................................................................................................................... 23Product Inspection ................................................................................................................................................ 24Standard Pin-on Coupler Removal ....................................................................................................................... 24End Cap, Lock Ring and Cross Port Relief Valve Removal ................................................................................ 26Shaft Removal ...................................................................................................................................................... 27Piston Sleeve Assembly Removal ....................................................................................................................... 28Seal and Bearing Removal .................................................................................................................................. 29Component and Timing Mark Inspection ............................................................................................................. 30
AssemblyDry Assembly ........................................................................................................................................................ 31Seal and Bearing Installation ................................................................................................................................ 31Piston Sleeve Installation ...................................................................................................................................... 35Shaft Installation ................................................................................................................................................... 36End Cap and Lock Ring Installation ...................................................................................................................... 37Cross Port Relief Valve Installation ....................................................................................................................... 39Standard Pin-on Coupler Installation .................................................................................................................... 39
Post AssemblyTesting and Greasing .......................................................................................................................................... 43
Warranty Information ............................................................................................................................................ 45Service Offering .................................................................................................................................................... 46About Helac Corporation ...................................................................................................................................... 48
INTRODUCTION
3
Product Overview
Helac PowerTilt®, a construction equipmentattachment from Helac Corporation, can increasethe productivity, profitability and versatility ofbackhoes or excavators by simply tilting theattachment instead of moving the entire machine.
PowerTilt is ideal for performing every day tasks, orcompleting jobs that haven’t been tried. Thousandsof contractors worldwide have come to rely onPowerTilt since 1990 for cleaning ditches, clearingland, digging beveled trenches, spreading rip-rap,and positioning brushcutters, mowers andhydraulic hammers.
When used in combination with Helac PowerGrip®,a multi-purpose bucket, companies can achieveunmatched, hand-like manipulation and dexterity,dramatically maximizing productivity.
INTRODUCTION
Content in this Instruction, Serviceand Repair Manual applies to allcurrent product models – PT,PTA or PTB Series – unlessnoted otherwise. For informationon maintaining, servicing orrepairing earlier product models –TT, TTB and TBB Series – pleasecontact your local dealer or HelacCorporation’s Service Departmentat +1 800 797 8458 (U.S. andCanada) or +1 360 802 1039(Worldwide).
Product Introduction
4
Specifications forPT, PTA and PTB Series
Product OverviewINTRODUCTION
PT Series
Standard housing with welded-onears. Lower end can be weldeddirectly to a quick coupler orbucket.
Custom Designs
Depending on the orderquantity, custom-engineeredconfigurations can be provided.
PTA/PTB Series
The housing and shaft aredesigned for customization. Idealfor integrating quick couplers atboth the top and bottom.PTA Series housing is designedfor welding; PTB Series housingincorporates drilled and tappedholes for bolt-mounting.
6 7 8 9 10 11 12
MaximumMachine Weight
10,500(4,775)
15,000(6,800)
20,000(9,100)
28,700(13,000)
45,000(20,000)
60,000(27,000)
75,000(34,000)
ApproximatePowerTiltWeight*
180 320 425 575 850 1,200 1,500(85) (145) (195) (260) (385) (545) (680)
Total Tilt 180°** 180° 180° 134° 134° 134° 134°
Model Size
25,000 42,000 63,000 94,000 130,000 165,000 220,000Output Torque(2,820) (4,740) (7,110) (10,620) (14,690) (18,640) (24,860)
(5,640) (9,480) (14,220) (21,240) (29,380) (37,280) (49,720)Holding Torque 50,000 84,000 126,000 188,000 260,000 330,000 440,000
* Weights may vary depending on model size. Approximate weights for PTA and PTB Series do not include mounting bracketsor couplers.
** Actual rotation may vary slightly.
lb(kg)
lb(kg)
in-lbs(Nm)
in-lbs(Nm)
Basic Configurations
5
Operation TechnologyINTRODUCTION
PowerTilt uses Helac Corporation’s innovative,sliding-spline operating technology to convert linearpiston motion into powerful shaft rotation. Eachactuator is composed of a housing and two movingparts — the central shaft and piston.
Starting position
The piston is completely bottomed out.Bars indicate starting positions of piston andshaft. Arrows indicate directions they willrotate. The housing with integral ring gearremains stationary.
Ending position
When hydraulic pressure is applied to thepiston, it moves axially, while the helicalgearing causes the piston and shaft to rotatesimultaneously. Applying pressure to theopposite port will return the piston and shaftto their original starting positions.
Helical spline teeth on the shaft engage matchingteeth on the piston’s inside diameter. A second setof splines on the piston’s outside diameter meshwith the gear in the housing.
6
General Safety Guidelines
1. PowerTilt should only be used to perform tasksfor which it was designed. Abusing the productand/or using it for purposes for which it was notintended can expose the operator and others tohazards as well as result in damage to thePowerTilt, carrier and/or other attachments.
2. Modification to the PowerTilt is done at theowner’s risk and may void the HelacCorporation, Attachments division warranty.
3. PowerTilt is designed for a maximum bucketwidth as noted below. Applying the full force ofthe excavator or backhoe to the corner of awide bucket (e.g. corner digging with a widebucket) may cause premature wear and/orreduced equipment life. It is also recommendedthat the bucket widths are not exceeded.
Before beginning disassembly of the PowerTilt,there are several cautionary notices that should beconsidered. If you are not comfortable with repair ormaintenance of this product, contact your localdealer or Helac Corporation’s Service Departmentfor assistance.
INTRODUCTION
Cautionary Notices Other Safety Guidelinesand Precautions
4. A decrease in breakout force may beexperienced due to the increased tip radiusand the added weight of the PowerTilt tothe stick.
5. It is the owner’s responsibility to be sure allsafety equipment is in place and operatingproperly at all times. If safety decals fade, aredamaged or become unreadable from adistance of 10 feet, they should bereplaced immediately.
47” ( 1,200 mm )55” ( 1,400 mm )59” ( 1,500 mm )66” ( 1,700 mm )70” ( 1,800 mm )82” ( 2,100 mm )94” ( 2,400 mm )
PowerTilt Model Maximum Bucket Width
Maximum Recommended BucketWidth for Use with PowerTilt
PT-6PT-7PT-8PT-9
PT-10PT-11PT-12
7
General Safety Guidelines
Be sure to post the warning decal provided byHelac Corporation to the cab of the carrier machine.
INTRODUCTION
Helac Corporation does not assume anyresponsibility beyond the design and performance ofits construction equipment attachment products.The customer is solely responsible for engineering ofmating structures, fasteners, and other associatedcomponents related to the installation of the productand its ultimate application.
Important Notice
6. PowerTilt should be used in conjunction withattachments that do not adversely affect thestability of the machine.
Product Identification
A unique serial number is located on eachPowerTilt.This serial number is stamped on thehousing and is also located on an Identification(ID) Tag. The serial number is located near thehydraulic ports, and may be required before partsand/or service issues can be resolved. It may benecessary to remove paint to expose the serialnumber.
8
Each PowerTilt is engineered for a specific backhoeor excavator and is designed to be pin mounteddirectly to the machine. When using the StandardPin-on Coupler, two sets of pins are required: oneset to mount the PowerTilt to the dipper stick and asecond set to mount the bucket or attachment tothe PowerTilt. When using Universal or HydraulicQuick Couplers, contact the respective couplermanufacturer for instructions and maintenance.
INSTALLATION AND MAINTENANCE
Do not attach a bucket or attachmentto the PowerTilt until the hydraulic toolcircuit for the PowerTilt is installed andoperating correctly.
Installation and Mounting
PowerTilt Installation
4. Slowly lift the PowerTilt to a safe height with thebucket and boom cylinders.
5. Curl the bucket cylinder until the PowerTilt anddipper holes align and install the bucket pivotpin. Rotate the pins as necessary and installthe required retainers.
PT Series — Installing the PowerTiltonto the Carrier
All PowerTilt models should be mounted to thecarrier according to the instructions outlined below.
1. Position the PowerTilt close to the carrier boomto ensure easy use of the lifting reach andrange of the carrier boom.
2. Lower the dipper to approximately 2-3 inches(50-75 mm) above the PowerTilt. Roll out thebucket cylinder to lower the link bars to thePowerTilt.
3. Align the PowerTilt and link bar holes andinstall the link pin.
9
Installation and MountingINSTALLATION AND MAINTENANCE
To mount a bucket or an attachment to thePowerTilt with the Standard Pin-on Coupler, followthe steps listed below.
1. Install the hook pin in the bucket or attachmentand position the bucket or attachment so thepin can be easily reached with the PowerTilthook as shown in the below image.
2. Hook the bucket pin, being sure the hook isproperly aligned to avoid damaging the hook.
3. Lift the bucket off the ground, then extend thebucket cylinder to pivot the PowerTilt until thesecond hole of the bucket or attachment alignswith the PowerTilt coupler pin hole.
4. Install the second pin and retain properly.
5. After mounting the bucket for the first time, thejacking bolt(s) on the back side of the hookrequire adjustment. Loosen the jam nut andthread the bolt until it touches the pin, thentighten the jam nut to lock the bolt in place.Proper adjustment will make it easier to alignthe mounting pins when changing buckets.
PT Series — Mounting a Bucket orAttachment to the PowerTilt
To remove a bucket or an attachment from thePowerTilt with the Standard Pin-on Coupler, followthe steps listed below.
1. Position the bucket or attachment so it islightly supported by the ground and in aposition so it will not move or fall when a pin isremoved. Remove the coupler pin (the pinfurthest from the cab).
2. Gently place the bucket or attachment on theground and move the PowerTilt away from thebucket or attachment to disengage completely.Use the bucket cylinder if necessary to makedisengagement easier. Be careful not todamage the PowerTilt hook while removing thebucket or attachment.
PT Series — Removing a Bucket orAttachment from the PowerTilt
Attachment Mounting
Attachment Removal
10
* Most PowerTilt models are manufactured with four ports: two ports (P1) and two ports (P2). The majority of all PowerTiltsdelivered to North American customers incorporate SAE port connections. PowerTilts delivered to customers outside of NorthAmerica incorporate BSPP port connections.
** PowerTilts are equipped with factory-installed integral cross port relief valves.
6 7 8 9 10 11 12
Hydraulic Requirements and Plumbing
Model Sizes
Hydraulic PressuresCross Port Relief Valve Pressure**Circuit PressureMaximum Circuit Back Pressure
3,200-3,300 psi (220-230 bar)3,650-3,750 psi (250-260 bar)580 psi (40 bar)
5/8(16)
32(525)
89(1,460)
118(1,935)
159(2,600)
215(3,515)
277(4,540)
in³(cm³)
gpm .8-1.5 (3-6)
1.5-3(6-12)
3-5(12-20)
6-7(24-28)
6-8(24-32)
8-11(32-44)
9-13(36-52)
4(1/4)
4(1/4)
6(1/4)
6(1/4)
6(1/4)
6(3/8)
in(mm)
3/8(10)
3/8(10)
1/2(12)
5/8(16)
3/8(10)
1/4(6)
1/4(6)
1/4(6)
3/8(10)
3/8(10)
3/8(10)
1/2(12)
62(1,060)
Displacement
RequiredOil Flow
Hydraulic Hoseand Tube SizingHose, Tube (Optional)
Whip Hose
Port Connections*
The Typical PowerTilt Circuit Chart and the Tool CircuitRequirements Table (shown on this page) illustrate thecontrol circuit requirements for the PowerTilt. Thehydraulic pressures and flow requirements mustbe observed or damage to the actuator can occur.
The installer of the PowerTilt is responsible for selectingthe control circuits that are compatible with theexcavator and meet the tool circuit requirements. Helaccan be contacted for additional control circuits andmethods for controlling the PowerTilt.
Most PowerTilts manufactured after1997 incorporate an integral crossport relief valve mounted inside theshaft. If this secondary relief does notexist then the circuit pressure mustbe lowered to match the cross portrelief valve pressure.
Each PowerTilt model is manufactured with twoports, P1 and P2. This is done to assist in the hoserouting. Refer to the Suggested Hose RoutingsDiagram on Page 12 for the recommended routings.
The majority of PowerTilts deliveredto customers in North Americaincorporate SAE type ports.Customers outside of North Americatypically have BSPP type ports.
Hydraulic Requirements
INSTALLATION AND MAINTENANCE
TypicalPowerTiltCircuit
Typical PowerTilt Circuit
Tool Circuit Requirements for PT, PTA, PTB Series
(liters/minute)
SAEBSPP
in(mm)
3/8(10)
6(1/4)
11
Hydraulic Requirements and PlumbingINSTALLATION AND MAINTENANCE
Plumbing When installing a new tool circuitor hydraulic lines, flush all the toolcircuit lines with hydraulic oil priorto connecting the PowerTilt. Thiswill remove any contaminants fromthe circuit components which mayhave accumulated duringmanufacturing and/or installation.
Hose and tube size recommendations can befound in the Tool Circuit Requirements Chartshown on Page 10.
The position of the hoses is important for reliableoperation. Refer to the Suggested Hose RoutingsChart on Page 12 for suggested hose routings.
Hoses should be routed between the housingbrackets and not through the openings in thebrackets adjacent to the ports which are used forthe manufacturing process. Depending on thegeometry of the installation, it may be advisable tocover the hoses with protective sheathing.
Connect hydraulic hoses to the appropriate portsusing fittings as shown on Pages 16 through 20.Be sure the hoses do not cross, foul, crush orchafe when operating the PowerTilt or machine.Verify proper hose routing for all possiblepositions of the PowerTilt and all attachments,which are to be used with the PowerTilt. Repairany oil leaks immediately.
12
INSTALLATION AND MAINTENANCEHydraulic Requirements and Plumbing
Suggested Hose Routings
13
MaintenanceINSTALLATION AND MAINTENANCE
1. Grease the thrust washers at the two greasefittings with a high quality Lithium-basedgrease. Apply grease until clean grease flowsfrom the grease reliefs. Severe operatingconditions such as abrasive dust or prolongedsubmersion in water may require more frequentgrease applications.
Daily
Weekly
Monthly
Never replace the grease reliefvalves with grease fittings or plugs.
Do not operate the PowerTilt if thegrease reliefs are not functioning.
Hydraulic fluid should be flushed through thePowerTilt. Position the PowerTilt so that the hydraulicports are facing downward. Swing the bucket to theend of rotation and then run the PowerTilt circuit overthe cross port relief valve setting for one minute tocompletely flush out all hydraulic fluid and anycontaminants which may have settled in thePowerTilt. Reverse the fluid direction and repeat sothat both sides of the piston are purged.
Check shaft end play. When the end playexceeds 0.015” (0.38 mm), the end cap must betightened according to the End Cap TorqueSpecifications Chart on Page 38.
2. Make sure the grease reliefs are functioningproperly. Open or replace non-functioninggrease reliefs immediately.
3. Inspect the PowerTilt for loose, worn ordamaged components and replace orrepair immediately.
4. Mounting pins should be greased uponinstallation and thereafter according to theequipment manufacturer's instructions.
The PowerTilt cannot be flushedunless the circuit pressure ishigher than the relief valve setting.
The end cap should not betightened more than 1/2 (one-half)turn total over the life of thethrust washer.
Tightening the end cap beyond 1/2 turn can causethe end cap to gall to the shaft. If excessive endplay still exists, the thrust washers should bereplaced. The end cap can be tightened usingeither of the methods outlined below.
1. Torque WrenchWith the lock ring removed, torque the endcap according to the End Cap Torque Chart onPage 38.
2. Hydraulic PressureWith the lock ring removed, torque by holdingthe end cap stationary and hydraulicallypressurizing Port P2 according to the End CapTorque Chart on Page 38. This procedure willrequire the use of a pressure gauge mountedeither in-line or to one of the P2 ports on thePowerTilt. For more information, contactHelac Corporation.
14
Troubleshooting GuideINSTALLATION AND MAINTENANCE
Problem Possible Cause Solution
PowerTilt does not hold position Excessive down pressure applied bythe excavator can cause buildup ofpressure in the PowerTilt which isopening the cross port relief valve.
Control valve leaking oil.
Faulty cross port relief valve.
Seals leaking oil.
This is normal. The integral cross portrelief valve is designed to protect thePowerTilt from excessive internalpressures that can damage the unit.
Test, repair or replace as needed.
Remove the integral cross port reliefvalve and visually inspect for damageor debris. Check pressure setting ofcross port relief valve: which can befound in the Tool Circuit RequirementsChart shown on Page 10.
Test and replace seals as needed.
PowerTilt swings in only one direction Single directional control valve isbeing used.
Cross port relief valve damaged.
Both lines connected to either both P1or P2 ports of PowerTilt.
Replace with bi-directional controlvalve.
Inspect, test and replace as needed.
Refer to Page 16 for proper portconnection location.
PowerTilt has spongy feel side to side Air in PowerTilt or hydraulic circuit.
Diameter of tubing/hoses larger orlonger than recommended.
Bleed air from circuit and check forcause.
Install new tubing/hoses withrecommended diameters.
Install pilot operated check valve inlines as close as possible toPowerTilt.
Forward and backward movement ofshaft in the housing (shaft endplay)
Worn or missing thrust washers. Tighten end cap according to the EndCap Torque Chart on Page 38. Replaceor install thrust washers if necessary.
Side to side bucket movement Some movement is normal due toclearance required between internalspline teeth.
Normal movement is 1° to 1-1/2°. Ifgreater, check shaft end play;excessive end play can contribute toside to side movement. If shaft endplay is not within acceptable limits,consult Helac Corporation.
PowerTilt will not accept greaseat fittings.
Grease relief valve is not functioning,or it has been replaced with a greasefitting or plug.
Clean or replace grease relief valves.
15
Tools Required
Several basic tools are required for thedisassembly and reassembly of the PowerTilt. Thesuggested tools are outlined below:
1. Brush
2. Customized end cap tool
3. Customized seal tools
4. Permanent marker
5. Flashlight
6. Hex driver
7. Hex wrenches
8. Large socket wrench
9. Plastic or rubber mallet
10. Plastic mandrel
11. Pry bar
12. Safety glasses
13. Threaded bolts
14. Torque wrench
1.2.
3.
5.
6.
7.
8.
14.
13.
12.
10.
9.
11.
TOOLS
4.
All fasteners are metric.
The seal tool is merely a customized standardflat head screwdriver.
1. Heat the flat end with a torch until it glows.
2. Secure the heated end of the screwdriverin a vise and bend the heated end to aslight radius.
3. Round off all sharp edges of the heated tipto a polished finish. The tool may be modifiedslightly to your own personal preference.
Making a Seal Tool
16
DRAWINGS
SEE PAGE 20
PT Assembly Drawing
17
PT Assembly Drawing
18
PTA Assembly DrawingDRAWINGS
SEE PAGE 20
19
PTB Assembly DrawingDRAWINGS
SEE PAGE 20
20
PT Piston DrawingDRAWINGS
*
*
* *
**
* Service normally not required.
*
*
21
PT Exploded ViewDRAWINGS
Housing with integral ring gear
Pistonsleeve
assembly
Shaft
End capLock ring
Standard pin-oncoupler
Shaft mounting screws
Plate washer
22
Parts List
Item Description Quantity
204 ....... Piston Seal ................................................ 1 For model sizes 10, 11 and 12 only.205 ....... Piston Seal ................................................ 1230 ....... End Cap O-ring .................................. 1 or 2231 ....... End Cap Back-up Ring ............................. 2232 ....... Piston O-ring ...................................... 0 or 1233 ....... Piston Back-up Ring .......................... 0 or 2234 ....... Piston Seal ................................................ 1235 ....... Piston Seal ................................................ 1 For model sizes 6, 7 and 8 only.237 ....... Exclusion Seal .......................................... 2238 ....... Pressure Seal ........................................... 2239 ....... Lock Ring O-ring ....................................... 1
SEAL KITSold as “kit” only.
TOOLS
BEARING KITSold as “kit” only.
Item Description Quantity
340 ....... Shaft Bearing ...................................... 2 or 3341 ....... Shaft Bearing ...................................... 1 or 2342 ....... Piston Bearing .......................................... 1343 ....... Piston Bearing ................................... 1 or 2344 ....... Thrust Washer .......................................... 2
Spare or replacement parts can be orderedonline at www.helac.com/service/parts.asp orby calling Helac Corporation’s ServiceDepartment at +1 800 797 8458 (U.S. andCanada) or +1 360 802 1039 (Worldwide),Monday through Friday, 7 a.m. to 4 p.m. PST.
When ordering Spare and Replacement Parts,including Seal and Bearing Kits, please havethe serial and/or model number available.These reference numbers are located on thePowerTilt ID Tag as noted on Page 7.
Order Your Spare andReplacement Parts Today
PARTSItem Description Quantity
1 ........... Housing ......................................................1 1.4 .... Ring Gear** ................................................02 ........... Shaft ...........................................................13 ........... Piston Sleeve .............................................14 ........... End Cap ......................................................15 ........... Lock Ring ....................................................16 ........... Standard Pin-on Coupler ............................1 PT Series only. 6.1 ... Torque Foot** .............................................0 6.2 ... Idler Foot** ..................................................0101 ....... Port Plug, Shaft ..........................................1104 ....... Shaft Mounting Screw* Model 6 M16 x 2.0 .............................4 Model 7 M20 x 2.5 .............................4 Model 8 M24 x 3.0 .............................4 Model 9 M24 x 3.0 .............................4 Model 10 M30 x 3.5 .............................4 Model 11 M30 x 3.5 .............................6 Model 12 M30 x 3.5 .............................6105 ....... Shaft Dowel Pin ..........................................1106 ....... Plate Washer ..............................................1107 ....... Grease Relief Cover ...................................2120 ....... Lock Ring Screw* Model 6 M12 x 1.75 ..........................6 Model 7 M12 x 1.75 ..........................8 Model 8 M16 x 2.0 ............................6 Model 9 M16 x 2.0 ............................8 Model 10 M16 x 2.0 ............................8 Model 11 M16 x 2.0 ............................8 Model 12 M20 x 2.5 ............................8121 ....... Piston Dowel Pin ........................................2122 ....... Grease Fitting .............................................2123 ....... Grease Relief .............................................2124 ....... Port Plug .....................................................4125 ....... Jacking Bolt, Coupler ......................... 1 or 2126 ....... Jam Nut, Coupler ................................ 1 or 2127 ....... Dowel Pin Retainer .....................................1129 ....... Lock Ring Set Screw ..................................2413 ....... Cross Port Relief Valve ...............................1450 ....... Hazard Warning Decal, for Product ............2451 ....... Hazard Warning Decal ................................1 For Cab
* All shaft mounting screws are Grade 12.9 / All lock ringscrews are Grade 10.9
** These parts are not available for purchase.
23
All numbers that appear inparenthesis ( ) in the followingsections are referring to items onPage 22.
Component IdentificationDISASSEMBLY
The PowerTilt is comprised of thefollowing components:
1. Housing with integral ring gear
2. Shaft
3. Piston sleeve assembly
4. End cap
5. Lock ring
6. Standard pin-on coupler
6.
4.2.
1.
5.3.
24
Product InspectionDISASSEMBLY
1. Begin with removing the port fittings and plugs(124) to drain the hydraulic oil into asuitable container.
2. When removing the standard pin-on coupler ortorque foot (6.1) and idler foot (6.2), remove thetorque foot mounting screws (104).
4. Unthread and remove the lock ring screws(120).
3. Secure the coupler using a hoist orsimilar device.
Standard Pin-on Coupler Removal
Make sure the PowerTilt is thoroughly cleanedprior to disassembly. Continue to clean allmachined parts in a wash tank and dry withcompressed air. Inspect the PowerTilt forcorrosion prior to disassembly.
Severe corrosion can make it difficult to removethe lock ring screws (120) or set screws (129) andunthread the end cap (04). If corrosion is evident,soak the screws with penetrating oil for severalhours before disassembly.
25
Standard Pin-on Coupler RemovalDISASSEMBLY
7. Using a hoist or similar lifting device, lift off thestandard pin-on coupler (06) or feet (6.1, 6.2).
There is an alignment dowel pin(105) between the shaft and thetorque foot (6.1) to prevent sliding.
5. Tighten the two lock ring set screws (129) intothe lock ring (05). Turn the set screws equally,backing the lock ring off the end cap (04) andidler foot (6.2).
6. Insert threaded bolts into the lock ring (05) andpull straight out.
26
End Cap, Lock Ring and Cross Port Relief Valve RemovalDISASSEMBLY
1. Unthread the port plug (101) on the end of theshaft to remove the cross port relief valve (413).
3. Unthread the end cap (04) from the shaft(02) using two bolts and a pry bar.
2. Remove the lock ring O-ring (239) fromthe shaft.
4. Remove the thrust washer (344) from theend cap (04) or the housing collar.
27
Shaft RemovalDISASSEMBLY
Do not remove the shaft (02) at thispoint. Component gearing isaligned for correct timing. Timing iscritical for correct operation ofthe PowerTilt.
2. Locate the timing marks on the housing ringgear (1.4), piston sleeve assembly (03) andshaft (02). Small punch marks are usually foundon the face of the piston teeth and ring gear.The shaft timing marks may be located in theroot or “V” of the helical gearing. Piston sleevetiming marks are best seen when the splinedend of the piston sleeve is flush with the ringgear inside the housing.
3. Remove the shaft (02) by rotating and slidingthe shaft gear teeth out of engagement with theinside diameter gear teeth of the piston sleeveassembly (03).
1. Rotate the shaft (02) completely clockwise,then slowly rotate the shaft counterclockwisewhile tapping the threaded end of the shaft tobegin removing the shaft from the piston sleeveassembly (03). Stop when the shaft gearingbecomes visible.
If you are unable to locate the factory-madetiming marks, use a paint stick or apermanent marker to mark the orientationbetween the housing ring gear, shaft andthe piston sleeve assembly.
28
Piston Sleeve Assembly RemovalDISASSEMBLY
1. Before removing the piston sleeve assembly(03), double check the timing marks of thehousing ring gear (1.4) in relation to the pistonsleeve assembly.
2. Using a rubber or plastic hammer and mandrel,gently tap the piston sleeve assembly (03) todisengage the O.D. gear teeth from the housingring gear teeth inside the housing bore.
29
Seal and Bearing RemovalDISASSEMBLY
1. Use the seal tools to remove all seals, wearguides and thrust washers (344) from the pistonsleeve assembly (03), end cap (04) andshaft (02).
Note that several product models may not havewear guides on the I.D. and/or O.D. of thepiston sleeve assembly (03).
All seals, bearings and thrustwashers (344) must bereplaced whenever the PowerTiltis reassembled.
2. Remove the grease fittings (122), grease reliefcovers (107) and grease reliefs (123).
30
Component and Timing Mark InspectionDISASSEMBLY
1. Clean all machined components thoroughly in awash tank and dry with compressed air.
2. Carefully inspect all critical areas: Sealgrooves, wear guide grooves, thrust surfaces,shaft surfaces, housing bore and gear teethfor any wear, corrosion and any other signsof damage.
3. Locate the timing marks on the shaft (02),piston sleeve assembly (03) and housing ringgear (1.4). Re-mark with a permanent markeror paint stick if needed.
31
Dry AssemblyASSEMBLY
In some cases, for repair personnel not familiar withthe assembly process, it may be beneficial toperform a “dry” assembly. This will provide a betteridea of how to properly align the gear teeth.A “dry” assembly is typically done without seals,yet requires the wear guides and thrust washers tobe installed.
Seal and Bearing Installation
Before installing seals and bearings, coat the sealsand machined surfaces with a high qualityhydraulic oil.
Before installing the end cap seals and bearings inthe below sequence, lay the end cap (04) on thetable with the inside facing up. Note orientation of allseals on assembly drawings before installing.
All seals, bearings and thrust washers(344) must be replaced wheneverthe PowerTilt is reassembled.
1. First install the O.D. exclusion seal (237).
End Cap Seals andBearing Installation
The exact location and number ofseals or bearings used varies byproduct model.
32
Seal and Bearing InstallationASSEMBLY
2. Lightly coat both sides of the thrust washer(344) with lithium grease and install on thethrust face of the end cap (04).
3. Next install the O.D. pressure seal (238) withthe lip facing inboard toward the hydraulicpressure.
4. Then install the wear guides (340, 341) in thewide groove of the end cap (04).
5. Now install the O-ring (230) and backupring (231) into the I.D. seal groove on theend cap (04).
33
Seal and Bearing InstallationASSEMBLY
2. For product models with cup and/or T-seals,install the seals on the O.D. and I.D. (234, 235)of the piston sleeve assembly. Note that thelips are facing away from each other on modelswith cup seals.
3. When used, install the wear guide(s) on theO.D. and/or I.D. (342, 343)
1. Before installing the cup seals on somePowerTilt models, remove the energizer O-ringfrom one O.D. and one I.D. seal and installthem nearest to the piston gearing. Failure todo so may cause premature seal wear andpressure trapping.
Piston Seal and Bearing Installation
34
Seal and Bearing InstallationASSEMBLY
4. Now install the wear guides (340, 341).
2. Lightly coat both sides of the thrust washer(344) with Lithium grease and install onto theshaft (02).
3. Then install the pressure seal (238) with the lipfacing inboard, toward the hydraulic pressure.
1. First install the exclusion seal (237) onto theshaft (02).
Shaft Seal and Bearing Installation
35
3. Confirm proper timing by aligning the pistonsleeve assembly (03) timing marks with thehousing ring gear (1.4) timing marks.
4. Then using a plastic or rubber mallet andmandrel, engage the piston sleeve (03) into thehousing ring gear (1.4). Continue tapping untilthe piston sleeve bottoms out against thehousing ring gear.
Piston Sleeve Installation
1. Before installing the piston sleeve assembly(03), coat the piston and housing bore withhigh quality hydraulic oil to reduce chance ofseal damage.
2. Carefully slide the piston sleeve assembly (03)into the housing (01). Gently tap the piston tocompress the seals through the housingchamfer. Continue tapping until the pistonsleeve contacts the housing ring gear (1.4).
ASSEMBLY
36
ASSEMBLYShaft Installation
1. Before installing the shaft (02), coat the shaftwith high quality hydraulic oil.
Temporarily cover the shaftthreads with tape to prevent sealdamage. Remove the tape afterthe shaft has been installed.
2. Insert the shaft (02) into the piston sleeveassembly (03), carefully aligning the timingmarks on the shaft with the piston (03). Takecare not to damage the I.D. piston seals (204,205) with the threaded end of the shaft.
4. Use a pry bar to rotate the shaft (02) in until itis completely bottomed out in the housing (01).
3. Verify timing marks before rotating the shaft allthe way into the housing (01).
37
3. Using a pry bar, continue to rotate clockwiseand tighten until the thrust washer (344) makescontact with the housing (01) collar.
5. Then install the lock ring (05), trying differentsplines to find the best alignment between thelock ring splines and the end cap (04) holes.If the holes do not align, thread the end cap byno more than one spline tooth to align the holes.
4. Remove the two screws and tighten the endcap (04) using a torque wrench and customizedend cap tool to the torque specifications shownon the End Cap Torque Chart on Page 38.
1. Before installing the end cap (04), coat the endcap and shaft threads with anti-seize grease.
End Cap and Lock Ring Installation
2. Install two screws into the end cap. Thread theend cap (04) onto the shaft (02) until the sealcontacts the housing.
ASSEMBLY
38
End Cap and Lock Ring InstallationASSEMBLY
6. Now make an alignment mark between the lockring (05) and shaft (02) splines. Then removethe lock ring.
End Cap Torque Specifications
06 350 – 500 475 – 680 510 – 610 35 – 40
07 550 – 670 750 – 910 510 – 610 35 – 40
08 1005 – 1205 1360 – 1630 610 – 810 40 – 55
09 1305 – 1605 1770 – 2175 510 – 610 35 – 40
10 1630 – 1955 2210 – 2650 510 – 610 35 – 40
11 2050 – 2455 2780 – 3330 510 – 610 35 – 40
12 2580 – 3100 3500 – 4200 510 – 610 35 – 40
Hydraulic pressurepsiModel Nm bar
Torqueft-lbs
39
Cross Port Relief Valve InstallationASSEMBLY
1. Reinstall the cross port relief valve (413) withnew O-rings and back up rings and torque to 44ft lbs (60 Nm).
2. Coat the shaft port plug (101) threads withLoctite 242 and install into the end of the shaft(02) and torque to 225 ft lbs or (305 Nm).
Standard Pin-on Coupler Installation
1. Reinstall the lock ring (05), aligning the timingmarks. Then install and tighten two screws intothe lock ring (05) to lock the end cap (04) andshaft (02) together.
40
Standard Pin-on Coupler InstallationASSEMBLY
4. Install the alignment dowel pin (105) into thetorque foot (6.1) if it is not already in place.
5. Then install the coupler (06) onto the shaft (02).Align the dowel pin (105) on the shaft to thetorque foot (6.1).
3. Remove the two screws and lock ring (05).
6. Coat the end of the shaft (02), the lock ring (05)and the outside of the end cap (04) withwaterproof grease.
2. Then using a pry bar, rotate the shaft until thetorque foot (6.1) mounting surface is horizontal.
41
Standard Pin-on Coupler InstallationASSEMBLY
7. Install the lock ring O-ring (239) onto the shaft.
8. Next install the lock ring (05) using twothreaded bolts as handles.
9. Coat the lock ring screw (120) threads withLoctite 242, install and torque per the FastenerTorque Chart on Page 42.
10. Coat the lock ring set screws (129) withLoctite 545, thread until tight and torque to 30ft-lbs.
42
Standard Pin-on Coupler InstallationASSEMBLY
11. Coat the torque foot screw (104) threads withLoctite 242 and install.
12. Torque the fasteners to the specificationsshown on the Torque Specifications Charts.
Fastener Torque Specifications
Torque Values for Port Plugs
23 +/- 111 +/- 118 +/- 1
100 +/- 12
31 +/- 1.515 +/- 1.525 +/- 1.5136 +/- 22
BSPP G1/4SAE-4SAE-6
SAE-20
23 +/- 118 +/- 127 +/- 2
100 +/- 12
31 +/- 124 +/- 1.537 +/- 3
136 +/- 22
Plug SizeTorque Value - Hollow Hex
Head PlugsNm
Torque Value - Hex HeadPort Plugs
ft-lbs ft-lbs Nm
Torque Values for Metric Fasteners
FastenerSize
Socket Head Bolt(grd 12.9)
Nm
* All Shaft mounting screws are Grade 12.9 / All Lock Ringscrews are Grade 10.9.
60 +/- 3103 +/- 5258 +/- 7
502 +/- 20868 +/- 27
1723 +/- 41
M10 x 1.50M12 x 1.75M16 x 2.00M20 x 2.50M24 x 3.00M30 x 3.50
44 +/- 276 +/- 4
190 +/- 5370 +/- 15640 +/- 20
1271 +/- 30
ft-lbs
44 +/- 375 +/- 4
187 +/- 5365 +/- 14630 +/- 20
1253 +/- 34
27 +/- .241 +/- .354 +/- .561 +/- 168 +/- 2
240 +/- 2360 +/- 3480 +/- 4
540 +/- 10600 +/- 15
Hex Head Bolt(grd 10.9)
Nm ft-lbs
Jam Nut(grd 12.9)
Nm ft-lbs
32 +/- 255 +/- 3
138 +/- 4269 +/- 10465 +/- 15924 +/- 25
43
Testing and GreasingPOST ASSEMBLY
Testing and Greasing
Attach the PowerTilt to either a hydraulic test benchor portable pump for greasing and testing. Makesure the PowerTilt is secured to prevent movement.Install the grease fittings, grease reliefs and covers.
1. After the PowerTilt is assembled but before itis put back into service, the exclusion sealsand thrust washers must be packed withLithium grease.
2. Locate the grease fittings (122) or ports on theend of the PowerTilt and using a grease gun,pack the exclusion seal and thrust washerwith grease until it exhausts from the greasereliefs (123).
3. Cycle the PowerTilt slowly and re-grease asnecessary. During testing, it is recommendedthe PowerTilt be cycled 20 to 30 times to checkfor leaks and the proper degrees of rotation.
If symptoms of poor performance develop, refer tothe Troubleshooting Guide on Page 15 for generalinstructions. If you need help with more specificapplication issues, contact Helac Corporation’sService Department.
It is the responsibility of your service technician toverify that the carrier and hydraulic circuit areoperating correctly. Because the PowerTilt receivesits power from the carrier, a thorough check of thecarrier hydraulic system is mandatory beforeperforming any PowerTilt service or adjustments.
Testing the Carrier'sHydraulic System
44
1. Connect a 5,000 psi (350 bar) test gauge intothe hydraulic line to Port P1. Pressurize untilthe shaft reaches the end of rotation andbottoms out externally, e.g. the shaft bracketor torque foot contacts the housing ormounting bracket.
If the shaft is not completelybottomed out, hydraulic fluidwill exhaust from Port P2 at ahigh velocity.
Testing for Internal Leakage
4. Check for leaks at Port P1 and around the mainshaft and end cap seals as in Step 2 above.
2. Remove and cap the hydraulic line to Port P2.Pressurize Port P1 to 2,500 psi (175 bar).Check for leakage at Port P2 and from aroundthe main shaft and end cap seals. Leaksindicate improperly installed parts.
3. Reconnect the hydraulic line to Port P2 andpressurize as in Step 1 above.
Testing and GreasingPOST ASSEMBLY
The integral cross port relief valve vents hydraulicoil around the internal piston assembly of thePowerTilt at approximately 3,100 to 3,400 psi (210to 230 bar).To test the valve:
Testing the Cross Port Relief Valve
1. Connect a 5,000 psi (350 bar) test gauge intothe line to Port P1. Pressurize until the shaftreaches the end of rotation and bottoms outexternally, e.g. the shaft bracket or torque footcontacts the housing or mounting bracket.
2. Relieve pressure to P2 and disconnect thehydraulic hose and cap it.
3. Install a temporary hydraulic hose to P2with the end of the hose vented to anappropriate container.
The cross port relief valve is set atthe factory and cannot be adjusted.
4. Slowly pressurize Port P1 noting the pressureat which oil flows from P2. The relief shouldvent at approximately 3,100 to 3,400 psi (210 to230 bar).
5. Test at Port P2 using the same procedure.
6. If test pressure does not meet specification, thevalve must be replaced. If piston seal leakageis suspected, relief port test plugs are availablefrom the factory.
45
Warranty InformationPOST ASSEMBLY
Helac Corporation warrants its products to be free from defects in material and factory workmanship for a period of two (2) years or 2,000 service hours, whichever occurs first, for applications defined as medium duty, on the machine for which the Helac Attachment (PowerTilt® or PowerGrip®) was originally designed and with cross port or work port relief valves installed according to Helac Corporation’s recommendations. The warranty period shall begin when the Helac Attachment is first placed into service as documented on the Warranty Registration Card. Parts and labor will be covered for the first 12 months or 1000 service hours after the start of the warranty period. Parts only will be covered for the remainder of the warranty period.
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, misapplication, negligence, accident, overload, field alteration, severe use or service applications beyond what the Helac Attachment was designed to perform. In no event shall Helac Corporation be liable for any incidental or consequential damages or claims including, but not limited to, the application in which the product was placed, field travel, freight charges, oil samples, downtime, etc. Warranty related repair and/or replacement issues will be satisfied according to how the product was originally purchased:
Sales Through Equipment DealersThis warranty covers labor at predetermined, fixed flat rates and repair or replacement of products or parts, which under normal use and service disclose defective material and factory workmanship. Claims under this warranty will be satisfied only by repair or replacement of the unit or any defective part there of. Products under warranty shall be returned to a factory authorized dealership location, transportation prepaid by the purchaser, for inspection by the dealer with factory consultation. Warranty repairs are only to be made at the selling dealer ’s location according to time maximums and at rates pre-established by Helac Corporation.
Direct Sales to End UsersThis warranty covers repair or replacement of product or parts, which under normal use and service disclose defective material and/or factory workmanship. Only repairs completed at the Helac factory or factory replacement (at Helac ’s option) will satisfy claims under this warranty. Products under warranty shall be returned to the Helac factory for evaluation and repair. The customer shall contact the Helac Warranty Department for a Return Authorization Number prior to shipping the product in question. The factory will not accept products returned without a Return Authorization Number. Transportation shall be prepaid by the purchaser. On receipt, Helac factory personnel will inspect the product for warrantable issue(s).Upon warranty acceptance, Helac Corporation will repair the warranty issue(s)of the product at no cost to the customer and return the product freight prepaid. If it is determined that the issue(s)are not covered by the warranty, the product (repaired or not) will be returned COD to the customer.
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. Helac Corporation reserves the right to alter this warranty and/or its terms at any time. 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.
46
Service OfferingPOST ASSEMBLY
Helac Corporation’s Service Department caneffectively tackle your service and repair needs andprovide responsive customer support. Our 30 yearsof extensive rotary actuator expertise coupled withan in-depth understanding of our customers’expectations, enables us to quickly and efficientlyservice your needs with the following three offerings:
Technical Support
Repair Service
Parts Service
Our service representatives have been trained toanswer the majority of your technical questionsduring the initial call. If your question can’t beanswered immediately, our representative will returnyour call quickly.
Call our Technical Support Department at+1 800 797 8458 (U.S. and Canada) or+1 360 802 1039 (Worldwide) from 7 a.m. to 4p.m. PST on weekdays (excluding holidays), ore-mail us at [email protected].
Our fully equipped repair department ensuresfactory specifications and customer expectationsare met quickly and efficiently. Helac PowerTilt andPowerGrip can be serviced through your localequipment dealer.
Call or e-mail our Repairs Department at+1 800 797 8458 (U.S. and Canada),+1 360 802 1039 (Worldwide) [email protected].
Our parts service team offers same day or 24 hourturnaround, depending on when the call is received,on all common items.
Spare parts can be ordered online atwww.helac.com/store, or by calling ore-mailing our Parts Department at+1 800 797 8458 (U.S. and Canada),+1 360 802 1039 (Worldwide) [email protected].
When ordering Spare and Replacement Parts,including Seal and Bearing Kits, please have theserial and/or model number available.
47
Notes
HELAC CORPORATION225 Battersby Avenue • Enumclaw, WA 98022 USAPhone +1 360 802 1039 • Fax +1 360 802 1030 • www.helac.com
®
About Helac Corporation
As a leader in the fluid power industry for over 30years, Helac Corporation manufactures acomprehensive line of hydraulic rotary actuatorsand construction equipment attachments. Helacrotary actuators are best known for theirtremendous torque output, compact dimensions,exceptional load bearing capability and rugged,
reliable performance. Helac PowerTilt andPowerGrip, two specialty products, increase theutilization of backhoes and excavators. Over 1,000worldwide customers in diverse markets dependon Helac's product lines to provide product quality,reliability, ease of use and durability.
PowerTilt - U.S. patent #4906161; Europe #356738;Japan #2614922
© 2012 Helac Corporation. All rights reserved.
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