Wiktor Wise
Electric linear actuators are present in almost every motor or machine. They can wear out due to frequent usage, harsh environments, vibrations, heavy loads, or electrical power issues. Repairs are often cheaper than replacements, and they can also help reduce material wastage. While some repairs can be done at home, there are also companies that provide repair services for a variety of linear actuators. This article will provide an overview of how to repair an electric linear actuator, including the tools required and the steps to take.
Repairing an Electric Linear Actuator
| Characteristics | Values |
|---|---|
| When to repair | When the motor fails due to age, improper operation, or burning out when electrical power was not turned off.) |
| When to replace | When there is severe damage or when the repair cost is higher than the price of a new actuator |
| Benefits of repairing | Cheaper than replacement, reduces material wastage, helps the user gain hands-on skills |
| Tools required | Screwdrivers, hammer, pliers, soldering iron, adjustable wrench, flathead screwdriver, wire cutters, vice or pliers |
| Steps | 1. Remove internals from tubular housing 2. Remove wire relief, endcap, and motor retaining ring 3. Unscrew and remove the motor cap mounting 4. Cut the cable at the shrink wrap 5. Remove the motor retaining ring 6. Remove the motor 7. Remove gears connecting the motor to the shaft 8. Remove the motor base screws 9. Cut the wires of the old motor 10. Insert new motor 11. Tighten the motor base screws |
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What You'll Learn
Removing internals from the tubular housing
The first step in removing the internals from the tubular housing of the actuator is to remove the wire relief, endcap, and motor retaining ring. The wire relief is divided into two parts: the retaining nut and the relief itself.
Using an adjustable wrench or 14mm wrench, unbolt the wire relief retaining cap and slide it all the way back down the wire. The plastic wire relief should now be exposed. With a counterclockwise twisting motion, turn and pull the relief until it is backed off completely and will not block the rest of the procedure. This part will get greasy, so have some shop towels and rubber gloves on hand.
Using an adjustable wrench or 20mm wrench, insert it onto the motor cap mounting and turn counterclockwise. Be mindful to let the actuator’s wires turn with the cap to avoid unnecessary tearing of the wire. Once unscrewed, back the cap off so it is out of the way. Cut the cable at the shrink wrap and set aside the cable external to the actuator.
Locate the two Allen screws preventing the motor retaining ring from spinning and back them off 2/3 of the way out of their threads. Secure the actuator firmly in a vice or have someone else hold the actuator so it does not rotate. Using a flathead screwdriver and a hammer, hit the screw in a fashion that will persuade the ring counterclockwise. Once the ring is free, unscrew it the rest of the way by hand. Be mindful that too much or hard hammering can damage the thread of the screw.
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Soldering wires
Soldering is an essential skill for repairing an electric linear actuator. Before soldering, ensure that the actuator is disconnected from any power source and not mounted. You will need a soldering iron and some electrical tape or heat shrink tubing.
First, you need to separate the limit switch assembly and stroke rod from the motor. To do this, use a drill with a chuck or a set of vise-grips to remove the stroke rod by twisting it counterclockwise. You may also need a screwdriver through the stroke rod mounting hole. Next, remove the retaining ring and rubber ring at the tip of the actuator. Depending on the actuator's position when it failed, you may need to use the vise-grips or drill to access the screws. Once you can see the screws, unsolder the wires at the two marked points and then remove the screws.
Now, trim and solder the wires to the bare wire on the limit switch block. Ensure you attach red to black and black to red. This will extend the rod with positive voltage on the red wire and retract the actuator with positive voltage on the black wire. Cover the solder points with electrical tape or heat shrink tubing.
At this point, the actuator is ready to be tested. Apply the appropriate voltage and test for proper extension and retraction. If the actuator does not depower at the end of the stroke, check your limit switch wiring.
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Removing the base cover
To remove the base cover of a PA-14 electric linear actuator, you will need a Philips screwdriver. First, use the screwdriver to completely remove the three base cover screws and washers by rotating them counterclockwise. Then, pull the base cover away from the rest of the actuator's body.
Once the base cover is removed, you will need to remove the gears that connect the motor to the shaft. It is important to do this in an organised manner so that the original orientation can be remembered. After removing the gears, you can then completely remove the three motor base screws by rotating them counterclockwise with the Philips screwdriver. This will allow the motor to become loose.
If you need to remove the old electric motor, you can use wire cutters to cut the two wires of the motor and then remove it. Pliers or a vice can be used to pry off the old electric motor gear wheel on the tip of the old motor. A bit of force and grip may be required for this step.
To put the base cover back on, simply follow these steps in reverse. Place the base cover back into its original place and secure it with the three base cover screws and washers by rotating them clockwise.
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Replacing the motor
Repairing an electric linear actuator can be a cheaper alternative to buying a new one. The motor can fail due to normal wear, misuse, or burning out when electrical power is not turned off.
- Disconnect the power source: Before beginning any work on the electric linear actuator, ensure that it is completely disconnected from its power source and not mounted in its application.
- Remove the internals from the tubular housing: This includes the wire relief, endcap, and motor retaining ring. First, unbolt the wire relief retaining cap with an adjustable wrench or a 14mm wrench and slide it back down the wire. With a counterclockwise twisting motion, turn and pull the relief until it is completely removed. Next, use an adjustable wrench or a 20mm wrench to turn the motor cap mounting counterclockwise.
- Remove the old motor: Place the actuator on a vice or similar block and use a punch to remove the pin. Keep the pin safe. Take out the old motor and put the new motor into the lead screw, lining up the hole on the motor shaft and lead screw. Put the pin through the two holes and ensure it is flush or under the lead screw on both sides.
- Cut the wire and reinstall the limit switch assembly: Cut the loop of wire coming off the top of the motor. Bring the limit switch block close to the motor side and thread the wires through the hole, as shown in the picture. Replace the small plastic spacers and slide the limit switch block into place, securing it with screws.
- Solder the wires: Solder the exterior wire of the actuator to the wire ends of the motor, attaching red to black and black to red. Cover the solder points with electrical tape or heat shrink.
- Insert the wire relief and thread the wire relief cap: Insert the wire relief into the housing, ensuring it grips onto the correct section (an indent in the wire will signify this point). Once in position, thread in the wire relief cap.
Note: This procedure is meant for someone who is electrically inclined and comfortable with soldering, mechanical work, and the use of tools like screwdrivers and wrenches.
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Tightening screws
When repairing an electric linear actuator, there are several instances where you will need to tighten screws. Firstly, when removing the base cover, you must first completely remove the three base cover screws and washers by rotating them counterclockwise using a Philips screwdriver. Then, to remove the motor, you must completely remove the three motor base screws by rotating them counterclockwise with the same type of screwdriver.
After removing the gears connecting the motor to the shaft, you can cut the wires of the old motor and remove it. To attach a new motor, you must push the electric motor gear wheel into place, and then tighten the motor back into place using the three motor base screws. This time, rotate the screws clockwise with a Philips screwdriver.
Additionally, when turning your attention to the shaft end of the actuator, you must remove the three Phillips screws securing the shaft seal plate and remove the plate. After exposing the seal, push the shaft end towards the back of the actuator and then pull it back. Finally, using the stroke rod end, push the motor assembly towards the back of the actuator and remove it completely from the tube housing.
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