RACK & PINION ACTUATORS
2R40 to 2R1750 Series
Installation & Maintenance Manual
5 October 24, 2013
www.atcontrols.com
Engineering\documents\products\IOM\IOM1003.docx
9.2 Installing the Pinion:
Lightly grease the pinion, o-ring grooves and guide bushing groove of the pinion and pinion o-rings
with multi-purpose grease. Install the top bearing into the actuator body bearing bore. Fit the top o-
ring into the top pinion groove. Fit the bottom guide bushing into the bottom pinion groove. Slip the
bottom o-ring into the bottom pinion groove. Carefully insert the pinion into the body until the top of
the Pinion is inside the body cylinder. Fit the travel stop cam over the top of the pinion and slide it
down until it is engaged with the pinion. (Note: The travel stop cam will engage with the pinion in only
one position.)
Gently push the pinion up through the body making sure the bottom guide bushing, bottom o-ring &
top o-ring stay in their grooves. With the pinion in this position install the thrust bearing washer, the
thrust washer and lastly the snap ring. Make sure the snap ring fits properly in the groove.
9.3 Alignment of Pinion for Correct Piston Installation:
Rotate the pinion to the position shown in Fig. 5 (When
viewed from the slot at the top of the pinion) ensuring
that the machined stop flats are in the correct
orientation.
9.4 Installing the Pistons:
Lightly grease the piston o-rings, piston backup ring &
guide plate with multi-purpose grease & fit the o-rings,
backup ring & guide plate into their respective grooves
on the piston. Liberally grease the actuator body bore
and the piston rack. Insert the pistons into the bore, one
piston in each end with the teeth facing each other (see
Figures 2, 3 & 4). (Note: The position of the Piston
determines the fail rotation of the actuator).
Push both pistons together until they are both in contact
with the pinion, so that when the pinion is rotated
(Clockwise for FCW, Counter Clockwise for FCCW) the
pistons are drawn together. When the pistons are together and the racks are correctly engaged with
the pinion, the top pinion drive flats should be several degrees past perpendicular to the body for
FCW, parallel to the body for FCCW.
9.5 Installing the Travel Stops:
With the pistons together, screw in the corresponding travel stop assembly complete with nut, washer
and seal until it comes into contact with the pinion. Rotate the pinion 90 degrees to drive the pistons
apart and screw in the other travel stop until it comes into contact with the pinion. After the end caps
are installed (see below) final adjustment is easily made when the actuator has been mounted to its
valve, damper or other device, depending on individual requirements. Ensure the nuts are tightened
against washer and seal.
Distributed by Relevant Solutions | 1.888.858.3647 | relevantsolutions.com
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