Bayne Revolution HD 1999-0520 Guide

1999-0520
OPERATION AND PARTS MANUAL
ISSUED JUNE 2017
CUSTOMER NAME: ____________________
SERIAL NUMBER: ____________________
1999-0520 Revision No. 001
LICENSED UNDER ONE OR MORE OF
THE FOLLOWING U.S. AND CANADIAN PATENTS:
5,503,512
4,773,812
1,327,765
5,447,405
1,335,648
5,308,211
5,333,984
5,826,485
© 2017 Bayne Premium Lift Systems .

WARNING
IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE
AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS
DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE
ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS
MANUAL FOR FUTURE REFERENCE
IMPORTANT SAFETY NOTICE
Proper service and repair are important to the safe, reliable operation of the Bayne THINLINE®
products. Service procedures recommended by Bayne THINLINE®are described in this
Operation and Parts Manual and are effective for performing service operations. Some of these
service operations may require the use of tools or blocking devices specially designed for the
purpose. Special tools should be used when and as recommended. It is important to note that
some warnings against the use of specific methods that can damage the product or render it
unsafe are stated in the service manual. It is also important to understand these warnings are
not exhaustive. Bayne THINLINE®could not possibly know, evaluate and advise the service
trade of all conceivable ways in which service might be done or of the possible hazardous
consequences of each method. Consequently, Bayne THINLINE®has not undertaken any such
broad evaluations. Accordingly, anyone who uses service procedures or tools which are not
recommended by Bayne THINLINE®must first satisfy himself thoroughly that neither his safety
nor the product safety will be jeopardized by the method he selects.

TABLE OF CONTENTS
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems Issued June 2017
Revision No: 001
........................................................................................................................................................................................2Safety
........................................................................................................................................................................................3Specifications
........................................................................................................................................................................................4Installation Instructions
........................................................................................................................................................................................10Operation Instructions
........................................................................................................................................................................................13Diverter Valve Information
........................................................................................................................................................................................15Maintenance Instructions
........................................................................................................................................................................................16Actuator Assembly Instructions
........................................................................................................................................................................................24Troubleshooting Chart
........................................................................................................................................................................................26Appendix A - Assembly Drawings and Part Numbers
........................................................................................................................................................................................271999-0520 - Revolution Lifter Assembly
........................................................................................................................................................................................36H5700009 - Revolution Specification
........................................................................................................................................................................................376900-0700 - Hydraulic Schematic
........................................................................................................................................................................................386900-0704 - Hydraulic Schematic
........................................................................................................................................................................................39M3500005 - Single/Dual Diverter Valve Parts
........................................................................................................................................................................................408000-0780 - Diverter Valve Seal Kit
........................................................................................................................................................................................416083-1010 - Single Hand Valve with Bracket
........................................................................................................................................................................................428000-0085 - Hand Valve Seal Repair Kit
........................................................................................................................................................................................43LUB4205B - Revolution HD Lubrication Points
...................................................................................................................................................................... 45
Index

INTENTIONALLY LEFT BLANK

Issued June 2017
Revision No: 001
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
1
PART NUMBER: 1999-0520 REVISION NO. 001
OPERATION AND PARTS MANUAL
ISSUED JUNE 2017

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Safety
2
SAFETY
WI-0070-A
To prevent serious injury, death or equipment damage, read and understand this entire manual before installing,
operating, repairing or adjusting your Bayne THINLINE®Premium Lift System. Those using and maintaining this
equipment must be thoroughly trained and familiar with the product.
A.Manual:
This manual must be kept in a location that is readily available for those who operate or maintain this equipment.
Additional copies may be obtained from your local dealer or directly from Bayne THINLINE®Premium Lift Systems.
B.Lockout/Tagout Procedures:
All applicable OSHA lockout/tagout regulations must be followed when working on this equipment. Failure to comply
with these procedures can result in serious injury or death.
C.Safety Decals:
Safety decals attached to your Bayne THINLINE®Premium Lift System warn of hazards related to the use of this
equipment. Operators must read and follow all safety instructions while using this equipment. If the safety decals are
not clearly readable, new decals may be obtained from your local dealer or directly from Bayne THINLINE®Premium
Lift Systems.

Issued June 2017
Revision No: 001
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Specifications
3
SPECIFICATIONS
WI-0502-A
A. Rotary Actuator - rack and pinion style design.
Rack, pinion, and shaft bearings are constantly lubricated by the hydraulic oil for extended life.
Body and caps are made of high quality ductile iron.
Pinion output shaft and racks are made of high tensile alloy steel.
The rotary actuator provides smooth motion throughout the lift cycle, which results in longer cart life with virtually no
cart damage or abuse.
B. The lift unit measures only 7-5/8” thick from the rear of the mainframe to the outer most point of the lift saddle in the
down position. This allows for easy dumping of large commercial containers without interference.
C.The cart is normally rotated to 51 degrees and placed over 13” inside the truck opening in the dump position thus
reducing any potential spillage of materials.
D.The lift unit operates at a cycle time of 8 to 10 seconds for safe, fast, efficient service.
NOTICE
Cycle time is controlled by flow rate, as flow rate increases, cycle times decrease.
WARNING
Never operate faster than the cycle time listed above to avoid injury and maintain manufacturer’s warranty.
E. Recommended flow rate is 2 to 2 1/2 GPM
F. Hydraulic pressure requirements are as follows:
1800 PSI normal working pressure
3000 PSI maximum pressure
G.All lifters can be a bolt on type installation for easy, quick maintenance and less downtime.
H.Three ( 3 ) year limited warranty from date of delivery on all units and models when properly maintained and operated
within the recommended cycle time.
NOTICE
All lift units and parts are inspected by our Quality Control Department before shipment to guarantee the highest
performance and satisfaction.
For more information, please contact us at 800.535.2671.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
4
INSTALLATION INSTRUCTIONS
WI-0252-A
The following information is intended to be a GENERAL GUIDE to installing the Bayne THINLINE®lifter on a typical
refuse truck. Before starting the installation, read these instructions completely. ALWAYS use the proper tools, lift
devices, and personal protective equipment to prevent injury while performing the installation.
NOTICE
If a Bayne THINLINE®Tap-In Kit was also acquired for this installation, refer to the installation instructions included in
the Tap-In Kit manual for more detailed information.
A.Mounting lifter(s) on the truck :
1. The truck should be emptied and cleaned before any installation. The truck should be parked on a level solid
surface, a concrete floor if possible.
2. All lights, tags, steps, etc. that will interfere with the installation should be removed and/or relocated.
3. Position the lifter(s) on the sill of the truck as in Figure below and mounting height drawing and tack weld in place.
See Appendix A for drawings. If using an “S” unit for bolt on applications, tack weld the mounting plate in place and
attach the lifter to the mounting plate using the 1/2” studs.
NOTICE
Tack weld only at this time so that adjustments can be made if necessary.
Figure 1 .

Issued June 2017
Revision No: 001
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Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
5
B.Mounting hand valve(s) on the truck :
1. Choose and mark an acceptable location(s) on the side(s) of the truck to mount the hand valve assembly(s) ( Figure
2 ).
2. Remove the mounting bracket(s) from the hand valve assembly(s) and weld to the truck.
3. After the weld has cooled, paint the mounting bracket(s) to match the truck color.
4. After the paint has dried, reassemble the hand valve assembly(s) on the mounting bracket(s).
Figure 2.
C.Mounting diverter valve on the truck :
1. Choose and mark an acceptable location to mount the diverter valve assembly. This location should be near the
truck’s main hydraulic pressure and tank lines on the same area of the truck where the lifter is mounted.
2. Weld diverter valve mounting bracket to the truck.
3. After the weld has cooled, paint the mounting bracket to match the truck color.
4. After the paint has dried, bolt the diverter valve to the mounting bracket using the 1/4” bolts, washers, and elastic
lock nuts.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
6
D.Making Hydraulic Connections :
Before attempting any hydraulic connections, turn the truck’s engine off and release all hydraulic pressure from the
system. Refer to the hydraulic layouts in the Figure below and hydraulic schematics while performing the following
steps. See Appendix A for drawings.
NOTICE
Always clean & lubricate fitting threads before installation.
Single Lifter Installation
Dual Lifter Installation
Figure 3.

Issued June 2017
Revision No: 001
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Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
7
D.Making Hydraulic Connections : (Continued)
1. Cut or disconnect truck’s main hydraulic pressure line and install the diverter valve in series using the “IN” and
“OUT” ports.
2. Connect the “T” port on the diverter valve to the truck’s hydraulic tank line with an appropriate size line to handle the
lifter system flow. (approximately 5 GPM max.)
3. Connect the “P1” port on the diverter valve to the “IN” port on the hand valve. If installing dual lifters, connect the
“P2” port on the diverter valve to the “IN” port on the other hand valve.
4. Connect the “T1” port on the diverter valve to the “OUT” port on the hand valve. If installing dual lifters, connect
the “T2” port on the diverter valve to the “OUT” port on the other hand valve.
5. Connect the “A” port on the hand valve(s) to the “UP” port of the rotary actuator(s).
6. Connect the “B” port of the hand valve(s) to the “DOWN” port of the rotary actuator(s).
7. Disassemble each hose clamp assembly and position weld plates where needed and weld in place.
8. After the weld has cooled, paint the weld plates to match the truck color.
9. After the paint has dried, reassemble the hose clamp assemblies around the hoses.
E.Adjusting relief valve settings :
The diverter valve ( 1 ) ( Figure 4 ) supplies the cart lifter hydraulic system with approximately 2 GPM of oil flow. This
diverter valve is equipped with a lifter circuit relief valve ( 3 ) set at 2300 psi, to prevent the diverter valve from shutting
down if a blockage occurs in the lifter circuit. There is also a relief valve ( 5 ) set at 1800 psi in the hand valve ( 2 ) to
protect the lifter from excessive pressure. These relief valves are preset from the factory to operate properly on most
trucks with a system pressure between 2300 and 2500 psi without any adjustment. However, if any adjustment is
necessary, follow these instructions.
WARNING
Bayne equipment is rated for a maximum pressure of 3000 psi. Operation at pressures above 3000 psi may damage
equipment and cause personal injury. In order to avoid injury and maintain manufacturer’s warranty never operate above
3000 psi.
Figure 4.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
8
E.Adjusting relief valve settings : (Continued)
1. Determine the truck’s system pressure setting.
2. Loosen the lock nut(s) ( 6 ) ( Figure 4 ) from the hand valve relief valve(s) ( 5 ) and turn the adjustment screw(s)
clockwise until it bottoms out.
3. Loosen the lock nut ( 4 ) ( Figure 4 ) on the lifter circuit relief valve ( 3 ) and turn the adjustment screw clockwise
until it bottoms out.
4. Start the truck’s engine and engage the hydraulic system.
5. Operate the handle on the hand valve ( 2 ) ( Figure 4 ) back and forth a few times to bleed all air from the lifter
hydraulic system.
6. Turn the truck’s engine off and release all hydraulic pressure from the system.
7. Install a 3000 psi hydraulic pressure gauge with the necessary adapter in the hydraulic line connected to the “IN”
port of the hand valve as shown in Figure 5. If installing dual lifters, install the hydraulic gauge at either one of the
hand valves.
Figure 5.

Issued June 2017
Revision No: 001
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Copyright 2017, Bayne Premium Lift Systems
Installation Instructions
9
E.Adjusting relief valve settings : (Continued)
8. Start the truck’s engine and engage the hydraulic system.
9. Setting the diverter valve lifter circuit relief valve :
a. Have an assistant hold the handle on the hand valve ( 2 ) ( Figure 4 ) ( with pressure gauge installed at the “IN”
port ) in the “retract” position to show pressure on the gauge.
b. Turn the pressure relief adjusting screw on the lifter circuit relief valve ( 3 ) counter-clockwise until the pressure
reading on the gauge is either 100 psi less than the truck system pressure or 2300 psi, which ever is the lowest.
c. Release the handle on the hand valve.
10.Setting the hand valve relief valve(s) :
a. Hold the handle on the hand valve ( 2 ) ( Figure 4 ) ( with pressure gauge installed at the “IN” port ) in the
“retract” position to show pressure on the gauge.
b. Turn the pressure relief adjusting screw on the hand valve relief valve ( 5 ) counter-clockwise until the pressure
reading on the gauge is either 200 psi less than truck system pressure or 1800 psi, which ever is the lowest.
c. Release the handle on the hand valve.
d. Turn the truck’s engine off and release all hydraulic pressure from the system.
e. Remove the hydraulic pressure gauge from the hydraulic line connected to the “IN” port of the hand valve.
f. For dual lifters, install the hydraulic pressure gauge in the “IN” port of the other hand valve as shown in Figure 5,
start the truck’s engine, engage the hydraulic system, and repeat step 10.
11.Reinstall the cap nut(s) ( 8 ) ( Figure 4 ) on the hand valve relief valve(s) ( 5 ) to secure the correct pressure setting
(s).
12.Tighten the lock nut ( 4) ( Figure 4 ) on the lifter circuit relief valve ( 3 ) to secure the correct pressure setting.
13.The hydraulic circuit pressures are now set for optimum performance.
F. Final operation and mounting:
1. Start the truck’s engine and engage the hydraulic system.
2. Place a cart on each lifter and operate to make sure there are no clearance problems and that the lifter engages the
cart properly. Make any adjustments to the mounting position of the lifter(s) to ensure correct operation.
3. After locating an acceptable mounting position, complete the welding of the lifter(s) to the truck.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Operation Instructions
10
OPERATION INSTRUCTIONS
WI-0430-B
The Bayne THINLINE®Premium Lift System is a high quality durable dumper built to meet industry requirements. To
insure the safety of all operators of this equipment, please read this manual carefully before operating the dumper.
FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY
DAMAGE.
The operating stages ( Figure 6 ) in the cycle of the cart lifter are as follows:
1. START - Inspect the cart for damage before engaging the latch mechanism, then place the cart at the lifter.
2. DUMP - The rotary actuator cycles to dump the contents of the cart into the box. During this cycle, the lower hook
automatically extends to “lock” the cart to the lifter.
3. RETRACT - The rotary actuator reverses its cycle returning the cart to the start position. The lower hook
automatically retracts to “unlock” the cart from the lifter.
Figure 6.
WARNING
Operating under the recommended cycle time on any lifter will void the manufacturer’s warranty
The rotational motions of the cart lifter are controlled with the use of a hand valve. Moving the handle on the hand valve in
one direction will cause the lifter to perform the actuator dump stage ( Figure 6 ). Moving the handle in the opposite
direction will cause the lifter to perform the actuator reverse stage.

Issued June 2017
Revision No: 001
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Operation Instructions
11
SAFETY ZONES
Stand Clear Zone
To prevent serious injury or death, operators and bystanders should remain outside the Stand Clear Zone ( Figure 7 ) at
all times during the operating cycle of the lifter. If at any point during the cycle persons enter this area, the operator most
stop all motion of the lifter until the area is cleared.
Dump Zone
To prevent serious injury or death, operators and bystanders should remain outside the Dump Zone ( Figure 7 ) at all
times. If it becomes necessary to enter this area, all applicable OSHA Lock-out/Tag-out regulations must be followed.
Operator Area
To provide a clear, unobstructed view of both the Stand Clear Zone and Dump Zone, operators should remain within the
Operator Area ( Figure 7 ) at all times during the operating cycle of the lifter.
Figure 7.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Operation Instructions
12
LIFT SADDLE ADJUSTMENT
The lift saddle is equipped with slots and must be properly adjusted to accommodate the carts being lifted. Check the
distance ( A ) ( Figure 8 ) between the upper bar and the lower bar on the cart. If this dimension is between 14-3/4” to 15-
1/2”, adjust the lift saddle spacing ( B ) as required to match the cart.
Figure 8.
CAUTION
It is the responsibility of the owner / operator of this equipment to adjust these dimensions to be compatible with his
specific application. If the bar spacing is not within the specified range, please contact us on available options for non-
standard carts.

Issued June 2017
Revision No: 001
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Diverter Valve Information
13
OPERATION AND INSTALLATION INFORMATION
WI-0026
The Bayne diverter valve establishes priority flow to the lifter circuit “P1” and “P2” ports and bypasses oil to the “OUT” port,
which typically supplies flow to the remainder of the truck’s hydraulic circuit. This bypass occurs only after the lifter circuit
is satisfied. The priority flow is controlled by the flow regulator cartridge (FR1) (and FR2 in dual applications) in
combination with the differential pressure sensing valve (DPS). This allows the valve to maintain constant flow regardless
of changes in load pressure or volume flow rate. Since both the lifter circuit and bypass flow can be utilized in the
operation of the truck regardless of which pressure is greater, a single pump can be used to supply two circuits or
operations.
The lifter circuit flow is regulated and maintained by the flow regulator cartridge (FR1) (and FR2 in dual applications). The
differential pressure sensing valve (DPS), rated for 75 gpm of flow and 3000 psi of pressure, is operated by an internal
spring and dampening orifice (OR) which establishes a pressure drop across the block sufficient to ensure the correct
operation of the flow regulator (FR1). For a dual diverter valve, a second flow regulator cartridge (FR2) is installed in the
“FR2” cavity and a shuttle valve (DSV) is installed in place of the SAE plug in the “DSV” cavity. Once the pressure drop is
established, a precision metered flow is provided to the tipper circuit(s) with additional flow being bypassed to the “OUT”
port.
The operation of the diverter valve does not require the use of a tank line to be run to the “T” port. However, the efficiency
of the block will be significantly increased if a tank line is installed. The logic circuit of the block will manage the flow of oil
returning from the tipper circuit to ensure optimum performance. This is primarily controlled with the sequence valve (PSV)
which is factory set and should not be adjusted. All oil returning from the tipper circuit will normally be regenerated into the
outgoing flow to ensure that the downstream functions are not slowed in any way. When the downstream backpressure
rises to a predetermined pressure, the block will redirect the flow to the “T” port to increase the overall efficiency of the
block and reduce the pressure drop through the block. If the “T” port is connected to a tank line, the oil will be dumped
through the block at a lower pressure. This allows downstream functions to operate at the highest possible pressure when
pressure is being required. If the “T” port is blocked, the oil will be redirected back into the outgoing flow through the check
valve (CV).
A relief circuit for the tipper function is controlled by a relief valve (RV), which is preset to 2300 psi. This can be adjusted to
limit pressure to the tipper(s). This relief valve is more efficient than the relief in the hand valve and will operate with less
noise. It is recommended that it be adjusted to relieve before the hand valve relief. It may also be used to limit the weight
the lifter can dump. This may be beneficial in avoiding damage to cans resulting from overloading. This should be the only
adjustment that the block may require. Any other adjustments should only be made after close consultation with Bayne’s
Engineering Department to ensure proper operation.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Diverter Valve Information
14
Possible Problems
1. The most common cause of valve failure is dirty oil. If debris becomes lodged in the cartridge valves they will
malfunction. Recommended filtration level is between 15 and 25 microns. Many systems filter the oil on the return
side. This does not guarantee clean oil going into the system. It is important to ensure that the tank vent filtration
element is properly maintained as well. Very small contaminants may not cause the valve to stop functioning, but
can cause “stiction” in the cartridges between the body and the moving spool. This can cause improper operation. A
slow moving tipper is most likely the result of contamination in the flow regulator cartridge. A pulsating noise may be
the result of contamination in the differential pressure sensing valve causing it to stick. If any valve malfunctions,
remove and thoroughly clean the valve, being extremely careful not to score or abrade the “o” ring seals or moving
parts of the valve. Be sure that the spool moves freely in the valve body.
2. The flow regulator cartridges (FR1 and FR2) are designed to operate at a designated pressure of 80 psi. This
means that in order for the valve to function properly, a minimum of 80 psi is required from the supply line through
the “IN” port of the valve. This can present a problem on trucks with a dry valve pump system. Normally in the dry
(off) mode of the pump, a flow of approximately 2 gpm at 20 psi is required to circulate through the open center
system of the truck. This is for pump lubrication in the off mode. When the diverter valve is placed in the main
pressure line of the truck, a blockage occurs because of the differential pressure sensing valve needing 80 psi to
initially open and allow the flow regulators function. The path of the lubrication oil is therefore stopped because the
valve does not open. When the oil is blocked, the pump will rotate and cavitate in the lubricating oil, causing heat to
build up over an extended period of time, possibly leading to premature pump failure. To prevent this problem from
occurring, a “bleed line” circuit needs be installed on the truck to allow passage of the lubricating oil back to tank.
3. On front load residential truck applications, several considerations need to be noted. The Bayne hand valve is an
open center valve that allows for the lifter circuit to maintain flow through the hand valve and back to the diverter
valve when the lifter is not being operated. If flow is not maintained through the hand valve, the oil will constantly be
relieving over the lifter circuit relief valve (RV) in the diverter valve, which can cause an increase in operating
temperature. Certain front load box designs allow for the hand valve to be located on the arms of the truck which
keeps the hand valve in the lifter circuit at all times to maintain flow. Most problems occur with applications where
the hand valve is located on the box itself. In this situation, when the operator disconnects the hydraulic lines to the
box, a blocked condition occurs in the lifter circuit. To prevent this problem, the pump must be turned off prior to
disconnecting the box hydraulic lines. Once the lines have been disconnected from the box, it is necessary to
connect the two lines for the hand valve to each other to functionally complete the lifter circuit. It is recommended
that male and female quick disconnects be used opposite each other on the truck to provide an uninterrupted circuit.
Once the lines have been connected and the circuit continued, the pump could then be turned on to continue
operations.

Issued June 2017
Revision No: 001
Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Maintenance Instructions
15
MAINTENANCE INSTRUCTIONS
WI-0140-A
NOTICE
The most common cause of hydraulic component failure is contamination of the hydraulic fluid ( water, chips, dirt, etc. )
The Bayne THINLINE®Lift System comes clean from the factory. If removed, be sure the hoses, cylinder and fittings are
clean before re-installing them on the unit.
Inspect your cart lifter on a weekly basis for loose bolts, fittings, oil leaks, etc. Tighten loose hardware as necessary and
replace necessary seals to repair oil leaks.
In order to maintain warranty and for preventive maintenance, grease all points every 40 hours or 2500 cycles (once
weekly) with a good multi-purpose grease at points shown in the lubrication drawing. See Appendix A for Revolution HD
Lubrication Guide.

Issued June 2017
Revision No: 001 Printed in U.S.A.
Copyright 2017, Bayne Premium Lift Systems
Actuator Assembly Instructions
16
ACTUATOR ASSEMBLY INSTRUCTIONS
1100 Series Roller Bearing Actuator, Part Number 1120-1045 ( WI-1135-B)
Licensed under on or more of the following U.S. Patents: 4,773,812 1,327,765 5,308,211 5,333,984
NOTICE
READ INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY.
Before starting the assembly of the Rotary Actuator, refer to the exploded parts drawing and parts list (Figure C-13 found
at the end of these instructions) to familiarize yourself with the individual components. Prepare a clean surface, in an area
free of blowing dust and contaminants in which to assemble the Rotary Actuator. Be sure that all parts are thoroughly
clean and dry before starting assembly.
NOTICE
All torque values given apply to clean dry threads only. Follow these directions closely when repairing the Rotary
Actuator.
1. Install the piston seal load ring (13) ( Figure 9 ) in the small groove on the head of the actuator rack (2). Place the
“square” piston seal (17) over the load ring (13) in the same small groove (a small “blunt” flathead screwdriver may
be used, taking care not to scratch or damage the seal). Install the wear ring (18) in the large groove on the head of
the rack. Using a ring compressor, firmly seat the rings on the rack before setting it aside, this will help to reverse
the effects of any stretching of the rings that occurred during installation. Repeat this procedure for the other rack.
Figure 9.
2. Install the tube seal (12) ( Figure 10 ) and “square” tube seal backup (16) on each end of the actuator tubes (3)
( Figure 21 ). Be sure that the “square” tube seal backup ring is toward the inside of the tubes at both ends as
shown. Press all rings firmly into the grooves. Repeat this procedure for the other tube.
Figure 10.