Duff-Norton TracMaster 6415 Series User manual

1
CAUTION!
This manual contains important information for the correct installation, operation and maintenance of the equipment
described herein. All persons involved in such installation, operation, and maintenance should be thoroughly
familiar with the contents. To safeguard against the possibility of personal injury or property damage, follow the
recommendations and instructions of this manual and keep it for further reference.
WARNING!
The equipment shown in this manual is intended for industrial use only and should not be used to lift, support, or
otherwise transport people.

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Contents
Section I Introduction
1-1. General.......................................................................................................................................3
1-2. Industrial Use Only....................................................................................................................3
1-3. Factory Preparation....................................................................................................................3
1-4. Warranty and Warranty Repair...................................................................................................3
1-5. Specications .............................................................................................................................3
Table1-1. 6415SeriesDCActuatorSpecications....................................................................................3
Table 1-2. 6415 Series DC Super Pac Actuator Duty Cycle.......................................................................3
1-6. DimensionsandSpecications ..................................................................................................4
Figure 1-1. LSPD-5415 DC Technical Illustration.......................................................................................4
Section II Installation
2-1. Installation Procedures...............................................................................................................5
2-2. Limit Switch Adjustment ...........................................................................................................5
2-3. Post-installation Procedures.......................................................................................................5
2-5. Digital Position Indicator...........................................................................................................6
Section III Operation
3-1. Operational Procedures..............................................................................................................6
Section IV Maintenance
4-1. Lubrication.................................................................................................................................7
4-2. Required Tools ...........................................................................................................................7
4-3. General Procedures ....................................................................................................................7
4-4. Disassembly ...............................................................................................................................7
4-5. Assembly....................................................................................................................................8
Figure 4-1. Potentiometer Nut and Washer Illustration................................................................................4
Section V Parts List and Technical Illustration
Table 5-1. Parts List for 6415 AC Actuator...............................................................................................12
Figure 5-1. Exploded Parts Illustration 6415 Series AC Actuator..............................................................13
Section VI Technical Illustrations
6-1. Brake Alignment ......................................................................................................................14
Figure 6-1A. Brake Spring, Motor and Pinion Coupling Alignment ............................................................14
Figure 6-1B. Brake Spring, Motor and Pinion Coupling Alignment ............................................................14
6-2. Limit Switch Wiring Diagram .................................................................................................14
Figure 6-2. Limit Switch Wiring Diagram, 6415 Series AC Actuator........................................................14
6-3. Limit Switch Assembly............................................................................................................14
Figure 6-3. Limit Switch Assembly, 6415 Series AC Actuator ..................................................................14

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Section 1
Introduction
1-1. General
This manual provides instructions for the installation,
operation and maintenance of the Duff-Norton 6415
Series DC actuator. It includes proper procedures for
the disassembly, cleaning, inspection, rebuilding and
assembly of the actuator. To ensure efficient, long,
satisfactory use of this unit, these instructions should be
followed closely.
1-2. Industrial Use Only
The actuators described and illustrated in this manual
are intended for industrial use only and should not be
used to lift, support or otherwise transport people, unless
you have a written statement from Duff-Norton Company
which authorizes this actuator unit, as used in your
application, as suitable for moving people.
1-3. Factory Preparation
Each actuator is carefully assembled and tested at the
factory to ensure that the motor and the mechanical
components will function properly and that the actuator
will lift its rated load.
The brake is preset at the factory and no further
adjustment is required. With proper maintenance, this
brake prevents the actuator from self-lowering.
The actuator is pre-lubricated at the factory and thus
requires minimum maintenance.
Limit switches are checked at the factory for proper
functioning.
External wires are provided for customer hookup. Wires
are color coded as to direction of travel of the actuator
(see wiring diagram, Figure 6.2).
1-4. Warranty and Warranty Repair
Subject to the conditions stated herein, Duff-Norton
will repair or replace, without charge, any parts proven
to Duff-Norton’s satisfaction to have been defective
in material and workmanship. Claims must be made
within one year after date of shipment. Duff-Norton will
not repair or replace any parts that become inoperative
because of improper maintenance, eccentric loading,
overloading, chemical or abrasive action, excessive heat,
or other abuse.
Equipment and accessories not of Duff-Norton’s
manufacture are warranted only to the extent that they
are warranted by their manufacturer, and only if the
claimed defect arose during normal use, applications
and service. Equipment which has been altered or
modified by anyone without Duff-Norton’s authorization
is not warranted by Duff-Norton. EXCEPT AS STATED
HEREIN, DUFF-NORTON MAKES NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE.
If you have any questions concerning warranty repair,
please contact the Duff-Norton Company.
Authorization for return must be received from the
Duff-Norton Company before returning any equipment for
inspection or warranty repair.
1-5. Specifications
Table 1-1. 6415 Series DC Actuator
Specifications
Applied
Load (lbs)
Speed
(in.min)
Amps Duty Cycle #
(in/hour)
Continuous
Duty* (in)
500 36 15 1500 1300
1000 31 21 750 300
1500 26 27 280 See Table 1-2
# Total inches of travel (up and down) per hour with
equally timed intervals between cycles.
* Total inches of travel (up and down).
Table 1-2. 6415 Series DC Super Pac
Actuator Duty Cycle
NOTE
Duty figures are based on 75˚F (24˚C) ambient
temperature. All ratings are nominal and are based on
actuator being broken-in for approximately 2500 inches
of travel

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Figure 1-1. LSPD-5415 DC Technical Illustration
1-6. Dimensions and Specifications
WARNING
1. Some actuator external surface temperatures may
reach 230°F at or near maximum allowable duty
cycle.
2. Do not operate actuator before setting limit switches.
3. Position hooded vent to prevent moisture and
dirt from entering actuator (see instruction and
maintenance sheet).
4. The actuator is not recommended for use in
applications where it can be jammed. Examples of
jamming include overtraveling the limit switches and
jamming the nut and screw internally at the extreme
ends of the stroke, or driving the actuator against an
immovable object and thus overloading the actuator
severely. Therefore consult Duff-Norton Engineering
if jamming is expected.
5. For fuse replacement use only Little fuse Part No.
511025 (5ag, 32 volt, 25 amp) medium acting fuses.
6. Do not place foreign objects in the fuse holder or use
fuses not recommended by Duff-Norton.

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Section II
Installation
2-1. Installation Procedures
Use Figure 6-2 as a guide to properly attach the SPA
6415 DC actuator to your power source. Duff-Norton’s
PDC series control box or 2 SPDT Relays must be used
to avoid burning up the limit switches.
2-2. Limit Switch Adjustment
CAUTION
Disconnect power before making any adjustments to
the limit switches.
IMPORTANT
Before attempting to set limit switch nuts by these
instructions, be certain that the red and blue motor
leads and the switch leads are connected properly
per Figure 6-2. Unless leads are connected exactly as
shown, the following steps will be meaningless.
1. Setting Retracted Position
a. Do not install actuator in the intended application
at this time.
b. With nut retainer “A” installed in actuator and the
translating tube unstrained, operate actuator toward
retracted position until limit switch nut “B” trips limit
switch (see Figure 6-3).
NOTE
Translating tube may jam and rotate prior to tripping
limit switch.
c. Rotate the translating tube by hand until distance
between the housing clevis hole centerline and
the translating tube clevis hole centerline equals
the desired closed height. This centerline to
centerline dimension is not to be less than the
retracted centerline to centerline dimension listed
in Figure 1-6. If the two clevis end holes are not
oriented as required, rotate the translating tube
no more than 1/2 turn in either direction until they
are properly oriented.
d. Install actuator in application and check drift.
Slight readjustment in switch actuation may
be attained by removing nut restrainer “A” and
rotating limit switch nut “B” (1 notch of rotation =
.05 in. of screw travel). Replace nut restrainer,
“A”.
2. Setting Extended Position
a. Restrain the translating tube against rotation
by hand. Operate the actuator, toward the
extended position, until the distance between
the housing clevis hole centerline and the
translating tube clevis hole centerline equals
the desired extended height. This centerline
to centerline dimension is not to exceed the
extended centerline to centerline dimension listed
in Figure 1-6.
b. Remove nut restrainer “A” and rotate limit switch
nut “C” (see Figure 6-3) until it activates the limit
switch.
c. Replace nut restrainer “A”.
d. Install actuator in application and check the unit’s
drift. Slight readjustment in switch actuation may
be attained by removing nut restrainer “A” and
(1) rotating limit switch nut “B” to adjust retracted
position or (2) rotating limit switch nut “C” to
adjust extended position (1 notch of rotation =
.05 in. of screw travel).
e. After adjusting limit switch nuts, replace nut
restrainer “A”. Operate the actuator and readjust
limit switch nuts as necessary to achieve desired
travel.
2-3. Post-Installation Procedures
After actuator installation, position the air vent to prevent
moisture and dirt from entering the actuator. Vent can be
repositioned by loosening the set screw and rotating the
outer air tube into which the air vent is threaded. Spot drill
and re-tighten set screw.
If necessary, an elbow (1/8” female x 1/8” male pipe
thread) can be used for more effective positioning
CAUTION
Do not engage potentiometer shaft gear teeth with
plastic worm before reading the following procedure.
Failure to adhere to the following procedure could
cause damage to the potentiometer.
4. Retract actuator translating tube until stopped by limit
switch.
5a. For travels up to 9” (single turn pot):
i. Turn pot shaft counterclockwise until resistance
between terminal S and CCW is approximately 100
ohms. This will be the pot’s full retracted position.
ii. Being careful not to turn the pot shaft, slide it into
engagement with the plastic worm and tighten locknut.

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iii. Re-check resistance. If necessary loosen locknut
slightly and twist pot to re-establish 100 ohm
resistance. Pot does not have end of travel
stops, but has a 20˚ deadband between the two
ends of the resistive element. No continuity will
be measured to terminal S if the slider is in the
deadband.
iv. Run actuator to full extension (do not let tube rotate)
until it is stopped by its limit switch.
v. Check resistance between S and CCW to be sure
the slider is still on the element and the resistance
is greater than 100 ohms. The pot has enough
rotation for 9.43 inches of travel. (For strokes
shorter than 9”, the retracted resistance can be
increased so that pot adjustment is less critical.
5b. For travels greater than 9” (multi-turn pot):
i. Turn pot shaft counterclockwise until it reaches
its stop. Now turn shaft back clockwise 1/4 turn.
ii. Without turning pot shaft, slide pot onto engage-
ment with the plastic worm and tighten locknut.
iii. Starting 1/4 turn from the end, the 3-turn pot has
enough rotation for 25” of actuator travel.
6. With this set-up, potentiometer will have increasing
resistance from S to CCW (and decreasing
resistance from S to CW) as the actuator extends.
2-5. Digital Position Indicator (Duff-Norton
part no. SK6300-4K)
The model SK6300-4K is a highly versatile, panel mount,
digital readout device that provides a very precise
indication of actuator position. It can be programmed
to display percentage, inches, or any other desired
unit. The indicator is self calibrating with no need for
measurements or calculations.
See detailed instructions with the SK6300-4K indicator for
installation and programming instructions. Potentiometer
terminal CCW should be connected to indicator Common,
CW to Excitation Voltage, and S to Signal Voltage Input.
Section III
Operation
3-1. Operational Procedures
This motor draws anywhere from 6 amps at no load to
27 amps at rated load. Make sure that the duty cycle to
which the actuator is subjected is not too severe for the
motor.
All wiring, switches, circuit breakers, etc. must be of
sufficient capacity to carry these currents. Avoid using a
voltage supply lower than 11 volts DC.
The axis of the clevis pins should be parllel so that the
actuator can pivot without binding. A few drops of oil
should be used on the clevis pins.
The preset brake will provide consistent braking for
the actuator. However, in the event the brake friction
surfaces become worn as indicated by excessive drift,
the brake will require rebuilding. To aid in rebuilding,
a repair kit with step by step instructions is available
through Duff-Norton Company under repair kit part
number SK-6415-41. The repair can be performed by the
customer or by any authorized repair station.
WARNING
This actuator is not recommended for use in
applications where it can be jammed. Examples of
jamming include overtraveling the limit switches and
thus jamming the nut and screw internally at the
extreme ends of the stroke, and driving the actuator
against an immovable object and thus severely
overloading it. This actuator can jam a limited
number of times without damage. Therefore, consult
Duff-Norton Engineering if jamming is expected.
Do not operate actuator before setting limit switches.
Some actuator external surface temperatures may
reach 230˚F at or near maximum allowable duty cycle.

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Section IV
Maintenance
4-1. Lubrication
Duff-Norton recommends the use of the following
lubricants in conjunction with proper maintenance
procedures of this unit, Mobile XHP-461 or XHP-462.
4-2. Required Tools
A bearing puller, press, soft jaw table clamp and common
hand tools are required for proper disassembly and
assembly.
4-3. General Procedures
Duff-Norton recommends following these procedures
during disassembly and assembly:
1. Tag critical parts to facilitate reassembly.
2. Mark mating surfaces to ensure proper meshing.
3. Clean and lubricate parts as required.
4. All seals must be replaced at time of rebuild, if
damaged.
5. All screws, washers and other small common parts
must be replaced if mutilated in any way.
4-4. Disassembly
Disassemble the 6415 Series DC actuator as follows
while referring to Figure 5-1. Read instructions thoroughly
before disassembling.
NOTE
Disassembly should be accomplished on a clean cloth.
1. Clamp actuator housing (42) in vise (use soft jaws).
Unit should be in horizontal position with outer tube
(55) up.
2. Remove screws (1) from limit switch box cover (11) and
remove limit switch box cover (11) and gasket (12).
3. Remove nut retainer (14).
NOTE
If unit has potentiometer assembly (26) and
potentiometer (26a) or gear (26b) is not damaged
proceed to Step 4.
a. Loosen nut (26c) and remove potentiometer
assembly from nut retainer (14).
CAUTION
Take care not to damage potentiometer when removing
gear.
b. Remove gear (26b) from potentiometer (26a).
Washer and nut do not have to be removed from
potentiometer (26a).
4. Remove screws (1) from capacitor box cover (2) and
remove cover (2) and gasket (3). Remove insulation
(4) from capacitor box.
5. Remove capscrews (71) from cover (9) and remove
fuse holder (70) from cover (9) (until lower terminal of
fuse is exposed). Remove fuse holder cap (70) and
fuse (72) from fuse holder body (70). Remove fuse
holder body (70) completely from unit.
6. Disconnect jumper wires (17 and 18) and motor
(53) lead wire terminals from switches (16). Remove
jumper wires (17 and 18) and pull motor (53) lead
wires into capacitor box.
7. Remove set screw (36) from housing (40).
8. Disassembly of Motor
a. Remove motor thru-bolts. (It is not necessary
to remove screws totally from motor.) With
screwdriver, pry (front end bell near housing)
motor (53) away from housing (42) (care must be
taken to prevent motor end bells from separating
from motor (53) shell and that motor lead wires
are not damaged).
b. Remove “O” ring (52) and rubber grommet (50).
9. Remove button head cap screws (7) and lock
washers (8). Remove cover (9) and gasket (41).
(Cover may have to be pried up with screwdriver, or
lightly tapped up with wooden or plastic hammer.)
Remove dowel pins (27).
10. Remove thrust washer (35) and thrust bearing
(36) from cover (9). Thrust washer (35) and thrust
bearing (36) may stay on spacer nut (37) in housing
(42) and can be removed in Step 18.
11. Remove limit switch shaft assembly, consisting of
limit switch shaft (22), limit switch nuts (23) and worm
(24), from cover (9). Allow limit switch shaft (22) to
drop out of flange bearing (25). Tilt shaft assembly
and remove from cover (9).
NOTE
If limit switch nuts (23) or worm (24) do not have to be
replaced, proceed to Step 14.
12. Thread limit switch nuts (23) off of limit switch shaft (22)
13. Remove worm (24) from limit switch shaft (22).

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NOTE
If switches (16), insulation (19) or limit switch bracket
(21) do not have to be replaced, proceed to Step 16.
14. Remove screws (20) and bracket (21) from cover (9).
15. Remove screws (15), switches (16) and insulation
(19) from bracket (21).
16. Press clevis end bushing (6) out of cover (9). If
bushing (6) is not damaged it should not be removed.
17. Remove bearing (28), bushing (34) and flange
bearing (25) from cover (9).
NOTE
Bushing (34) and flange bearing (25) should not be
removed unless they are damaged. Bearing (28) may
stay on pinion (29) and can be removed in Step 18.
18. Remove thrust washer (31) from intermediate pinion
shaft (32). Bearing (28) from pinion (29), thrust
washers (35) and thrust bearing (36) from spacer nut
(37) may have been removed in Step 10.
19. Remove spring (61) from end of screw (62).
20. Remove intermediate cluster gear (33), intermediate
pinion shaft (32) and thrust washer (31).
21. Remove socket head cap screws (45), lock washers
(46)
22. Disassemble outer tube (55) and slip off over
translating tube and clevis (66).
23. Remove air vent (58), wiper scraper (60) and guide
bushing (59) from outer tube (55).
NOTE
If wiper scraper or guide bushing are not damaged they
should not be removed.
24. Remove set screw (68) from spacer nut (37) and
disassemble spacer nut (37) from screw (62) by
clamping screw (62) between soft jawed vise.
WARNING
Care must be taken not to damage bearing journal
of spacer nut (37).
25. Remove output gear (39), key (40), thrust washers
(35), thrust bearing (36), and gear spacer (43).
26. Remove screw (62), translating tube and clevis (66)
and nut assembly (64).
27. Remove washer (44) from screw (62).
28. Thread screw (62) into the translating tube until the
screw bottoms out and cannot rotate farther, or until
the screw thread becomes disengaged from the
lifting nut thread (64).
29. Drive the four pins (65) just far enough into the
lifting nut (64) to clear the translating tube wall; then
remove the translating tube from the nut.
30. Remove the lifting screw (62) from the lifting nut (64)
31. Remove the four pins (65) by pressing each one the
rest of the way through the lifting nut wall.
32. Remove the stop pin (63) from the lifting screw (62) if
necessary.
33. Removing the brake. (Required only if drift is
excessive. If brake removal is not necessary,
proceed to Step 34).
a. Push on the pinion coupling (48) until it slips
back enough to make the spring (49) tang
accessible.
b. Remove the spring (49) by grabbing the tang
with pliers and twisting out. (Spring must now be
replaced and can no longer be used.)
c. Remove retaining ring (48) from input pinion (29)
and remove coupling (47). Input pinion (29) and
bearing (30) now can be removed from housing (42).
d. The brake inset (51) has straight knurls on its O.D.
which prevent it from rotating. Therefore, the insert
can only be removed by pulling straight out.
e. One method of removing the insert (51) is to use
a blind hole bearing puller. This tool expands into
the internal spring cavity and pulls against the lip
of the insert (51).
34. If coupling (47) on motor (53) shaft must be replaced,
remove retaining ring (48) from motor (53) shaft and
remove coupling (47).
DISASSEMBLY IS COMPLETE.
4-5. Assembly
Assemble the 6415 Series DC actuator as follows while
referring to Figure 5-1. Read instructions thoroughly
before assembling.
NOTE
Be sure all components are clean and dry before
assembling.
1. Install V-Ring Seal (5) on motor (53) shaft. (Cup end
of seal should be against motor end bell. Care must
be taken not to collapse V-ring.) Assemble coupling
(47) on motor shaft, then install retaining ring (48) on
motor shaft.
2. Press bearing (30) on input pinion (29) (press load
should be applied to inner race of bearing to avoid

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damage to bearing).
3. Press bushing (34) into housing (42).
4. Install input pinion (29) and bearing assembly (30) in
housing (42) (press load should be applied to outer
ring of bearing to prevent damage to bearing).
5. Assemble coupling (47) on input pinion (29) and
install retaining ring (48).
6. Brake Assembly
a. Grease O.D. of spring (49) and pocket of insert
(51) (chamfered end) with Aeroshell #6 grease.
CAUTION
When using replacement parts, make sure you have
correct spring. Red spring designates DC unit.
b. Install spring (49) into insert (51) pocket
(chamfered end).
c. Align pinion coupling (47) and spring (49) as
shown in Figure 6-1A and press insert (51)
and spring (49) assembly into housing (42)
(alignment must be as shown in Figure 6-1A).
7. Press bushing (34), bushing (6) and flange bearing
(25) into cover (9).
8. Assembly of Limit Switch Components (refer to
Figure 6-3).
a. Assemble insulation (19), limit switch (16) and
screw (15) on limit switch bracket (21).
NOTE
Limit switch (16) leads should face each other.
Insulation (19) should be folded up and behind
common terminal of switches (16). See Figure 6-3.
b. Assemble limit switch nuts (23) on limit switch
shaft (22) (care should be taken not to cross-
thread nuts). Nut hubs should be facing away
from each other. See Figure 6-3.
c. Assemble worm (24) on limit switch shaft (22).
Unthreaded hub on worm should be away from
limit switch shaft (22) threads. (See Figure 6-3.)
9. Assembly of Limit Switch Components in cover.
Refer to Figures 6-2 and 6-3.
NOTE
Cover (9) should be in a soft-jaw vise with limit switch
box cover up.
10. Assemble limit switch bracket (21), insulation (19) and
switch (16) assembly into cover (9) with screws (20).
11. Assemble limit switch shaft (22), limit switch nuts (23)
and worm (24) assembly into cover (9). Tilt shaft and
insert into I.D. of bushing (34). Then straighten and
assemble shaft into flange bearing (25).
NOTE
Worm (24) should be facing up toward flange bearing
(25). See Figure 6-3 (shaft will be loose in cover).
12. Attach red terminal wire (17) to common terminal of
left side switch (16). Attach blue terminal wire (18) to
common terminal of right side switch (16). Feed ends
of terminal wires (17) and (18) through 5/8” dia. hole
into cover (9) capacitor box.
13. Press guide bushing (59) and wiper scraper seal (60)
into outer tube (55). (Scraper part of scraper seal
should be facing outward away from guide bushing.)
14. Install the stop pin (63) in the end of the lifting screw
(62), taking care to center the pin in the screw.
15. Screw the lifting nut (64) on to the lifting screw (62)
with the flange end away from the stop pin (63).
16. Fill the translating tube (66) approximately 1/2 to 3/4
full with Duboise M.P.G. grease (no substitutes).
17. Slide the translating tube over the lifting screw (66)
and on to the lifting nut (64), lining the four holes in
the translating tube up with the four holes in the lifting
nut (64). Install pins (65) flush with translating tube
O.D.
18. Assemble washer (44) and gear spacer (43) on
screw (62). Install key (40) in key groove of screw.
19. Clamp sides of housing (42) in vise (use soft jaws
with input pinion up).
20. Install screw (62), gear spacer (43), washer (44),
translating tube (66), and tube nut (64) assembly into
housing (42) through bushing (34).
21. Apply a generous amount of Aeroshell #6 grease (no
substitutes) to thrust washers (35) and thrust bearing
(36) and assemble over gear spacer (37).
22. Aligning keyway in output gear (39) with key (40)
in screw (62), assemble output gear (39) on screw
(counter-bore in gear facing up away from thrust
bearing).
23. Clamp screw (62) between soft jawed vise. Thread
spacer nut (37) on screw (62) and tighten against
output gear (39). Spacer nut flange should be in
counterbore of output gear. Do not grip on bearing
journal of spacer nut when tightening spacer nut.
24. Check alignment of tapped holes in spacer nut (37)
with holes in output gear (39). Use two 9/64 dia. pins
approximately 11/2” long. One pin should drop into

10
hole in output gear (39). If pin does not drop into
hole, tighten or loosen spacer nut until hole is aligned
and one pin drops into hole. (Note: spacer nut should
not be rotated more than 221/2 before pin drops into
hole in gear.) It is preferable to tighten spacer nut
down instead of loosening.
25. Remove pin from aligned hole. Install half dog set
screw (68) and tighten half dog point into hole i
output gear (39). Remove remaining pin and proceed
with assembly. Note: One hole must be in alignment
to have proper assembly.
26. Lightly grease O.D. of translating tube (66) with
Duboise M.P.G. grease (no substitutes) and
assemble outer tube (55) assembly over translating
tube (66) and thread into housing (42) (a sealing
compound such as Non-Hardening Permatex 2
should be used on threads).
27. Insert intermediate pinion shaft (32) in housing
(42) and place thrust washer (31) over shaft (32).
Assemble intermediate cluster gear (33) on shaft and
place thrust washer (31) on top.
28. Assemble bearing (28) on input pinion (29) (press on
inner bearing ring to prevent damage to bearing).
9. Pack housing (42) gear box cavity with Aeroshell #6
grease (no substitutes).
30. Assembly of Motor (53) to Housing (42)
a. Note location of flat on input pinion (29) by
marking spot on the coupling (47) posts. See
Figure 6-1B on page 14.
b. Insert grommet (50) on input pinion (29) between
coupling (47) posts and install “O”-Ring (52) in
cavity of insert (51).
c. Pack cavity with Aeroshell #6 grease.
d. If hole plug (54) is in rear end of motor, remove.
e. Feed motor (53) lead wires through hole in
housing (42) lining up couplings (47) on input
pinion (29) and motor (53) shaft. (See Figure
6-1B on page 14.) Motor screws should be lined
up with tapped holes in housing (42).
NOTE
Alignment is critical at this point. See Figure 6.1B on
page 14. Note that input pinion (29) and motor (53)
shaft flats are opposite each other.
f. Assemble motor (53) into housing and install
screws (care should be taken during assembly
that end bells do not separate from motor (53)
shell).
g. With a screwdriver turn motor shaft by inserting
in motor shaft slot in end of motor. If couplings
are properly installed, the shaft will turn freely in
both directions. If motor shaft will not turn, this
is an indication that a couplings are not properly
installed.
31. Insert intermediate pinion shaft (32) in housing
(42) and place thrust washer (31) over shaft (30).
Assemble intermediate cluster gear (33) on shaft and
place thrust washer (31) on top.
32. Assemble bearing (28) on input pinion (29) (press on
inner bearing ring to prevent damage to bearing).
33. Pack housing (42) gear box cavity with Aeroshell #6
grease (no substitutes).
34. Insert dowel pins (27) in housing (42) and place
gasket (41) in place over dowel pins (27).
35. Install air vent (58) in outer tube (55) ( it may be
necessary to back outer tube out in order to install air
vent or to have vent in a more desireable position).
Spot drill tube and install set screw (38) to hold tube
in place.
36. Install spring (61) into end of screw (62).
NOTE
If unit has potentiometer assembly (26) and gear
(26b) does not have to be replaced or if unit has no
potentiometer feature, proceed to Step 35.
37. Potentiometer Assembly (26)
a. If nut and washer were removed from
potentiometer, assemble washer (26d) and nut
(26c) on potentiometer (26a). Nut (26c) should
not be tightened on potentiometer (26a) face.
b. Assemble gear (26b) on potentiometer (26a
shaft.
NOTE
Gear should be assembled with a very light press. See
sketch for required dimension of gear on potentiometer.
Take care not to damage potentiometer.

11
Figure 4-1. Potentiometer Nut & Washer
38. Asembly of Fuse Holder in Cover (9)
a. Connect jumper wire (69) to one terminal of fuse
holder body (70a).
b. Install fuse holder body (70a) into cover.
c. Apply Permatex 2 Non-Hardening Sealant to
threads of cap screws (71) and install in cover (9)
to fasten fuse holder body (70a) in place.
39.Assembly of DC Cover
a. Connect motor lead wire to other terminal of fuse
holder body (70a).
b. Feed motor (53) lead wire with terminal and
jumper wire (69) terminal thru cover (9) (care
should be taken not to damage wires). Assemble
cover (9) on housing (42) aligning dowel pins
(27) with dowel pin holes in cover (9). (A light tap
with a soft hammer may be required.)
c. Install lock washers (8) and button head cap
screws (7).
d. Install fuse (72) in fuse holder cap (70) and install
assembled fuse (70B) and body cap into fuse
holder body (70A).
e. Feed terminal wires, (17) red, (18) blue, fuse
jumper wire, and motor lead through 1/2” tapped
hole in cover capacitor box outside of cover.
f. Insert insulation (4) and assemble gasket (3) and
cover (2) with screws (1).
g. Adjust actuator limit switch settings per
instructions in paragraph 2-2.
h. If actuator has potentiometer, refer to position
indicator installation and calibration instructions
in Paragraph 2-4.
I. Attach gasket (12) and cover (11) with screws
(1).
ASSEMBLY IS NOW COMPLETE.

12
Section V
Parts List and Technical Illustration
Table 5-1. Parts List for 6415 AC Actuator
Index
No. Part Name Qty. Req.
Part
Number
1
2
3
4
5
Screw
Cover
Gasket
Insulation
V-Ring Seal
8
1
1
1
1
H-2979
SK-6415-38
SK-6415-37
SK-6415-47
SK-6415-95
6
7
8
9
10
Bushing
Button Head Cap Screw
Lock Washer
Cover
Tapered Closure
1
5
5
1
1
SK-6415-96
H-2986
S-42-9
SK-6515-91
SK-6000-46
11
12
13
14
15
Switch Cover
Gasket
Instruction Decal
Nut Restrainer
Screw
1
1
1
1
4
SK-6415-36
SK-6415-35
SK-6905-15
SK-6415-136
H-2984
16
17
18
19
20
Switch
Jumper Wire (Red)
Jumper Wire (Blue)
Insulation
Screw
2
1
1
2
2
SK-6415-131
SK-6415-32-1
SK-6415-32-2
SK-6415-132
H-2979
21
22
23
24
25
Limit Switch Bracket
Limit Switch Shaft
LImit Switch Nut
Worm
Flange Bearing
1
1
2
1
1
SK-6415-137
SK-6415-135
SK-6425-9
SK-6905-3
SK-6425-11
26
26a
26b
26c
26d
Potentiometer Assembly
Potentiometer
Gear
Nut
Lock Washer
1
1
1
1
1
††
††
SK-6415-62
furnished with
26a
27
28
29
30
31
Dowel Pin
Bearing
Input Pinion
Bearing
Thrust Washer
2
1
1
1
2
H-5391
SK-6415-5
SK-6415-3
SK-2374-5
255K14
32
33
34
35
36
Intermediate Pinion
Shaft
Intermediate Cluster
Gear
Bushing
Thrust Washer
Thrust Bearing
1
1
2
4
2
SK-6415-9
SK-6415-4
SK-6415-11
255K10
511K11
Index
No. Part Name Qty. Req.
Part
Number
37
38
39
40
41
Spacer Nut
Set Screw
Output Gear
Woodruff Key
Gasket
1
1
1
1
1
SK-6415-17
H-2594
SK-6415-92
S-23-12
SK-6415-7
42
43
44
45
46
Housing
Gear Spacer
Washer
Socket Head Cap Screw
Lock Washer
1
1
1
3
3
SK-6415-1
SK-6415-91
H-4011
S-49-94
H-4081-P
47
48
49
50
51
Coupling
Retaining Ring
Spring
Rubber Grommet
Insert
2
2
1
1
1
SK-6415-20
SK-2374-8
SK-6415-69
SK-6415-29
SK-6415-68
52
53
54
55
56
“O”-Ring
Motor
Hole Plug
Outer Tube
Warning Decal
1
1
1
1
1
X-6477-63
SK-6415-8
H-7827
SK-6415-111**
SK-6415-86
57
58
59
60
61
Actuator Deal
Air Vent
Guide Bushing
Wiper Scraper
Spring
1
1
1
1
1
SK-6415-67
SK-2015-218
SK-6415-23
SK-6415-16
JF-343-3
62
63
64
65
66
Screw
Stop Pin
Nut
Pin
Translating Tube
& Clevis
1
1
1
4
1
SK-6415-113*
H-5122
SK-6415-15
H-5164
SK-6415-109-A*
68
69
70A
70B
71
72
Half Dog Set Screw
Jumper Wire
Fuse Holder Body
Fuse Holder Cap
Cap Screw
Fuse
1
1
1
1
2
1
H-2612
SK-6415-129
SK-6415-128
SK-6415-128
S-49-94
SK-6415-103
* Denotes dash number is equal to travel
** Denotes dash number is 3 for travel. 3 inches or less.
Otherwise denotes dash number is equal to travel in
inches.
†† Optional
Travel Potentiometer
(26a)
Ohms Ohms/
Inch
Change
Potentiometer
with gear (26)
9” or less SK-3275-24 5000 530 SK-6415-70-10A
Over 9” SK-6200-18 5000 167 SK-6415-70-5A

13
Figure 5-1. Exploded Parts Illustration 6415 Series AC Actuator
WARNING
Use only replacement parts supplied by or
approved by Duff-Norton. Non-authorized parts
may be inadequate, resulting in serious injury or
death in event of failure.

14
Section VI
Technical Illustrations
6-1. Brake Alignment
6-2. Limit Switch Wiring Diagram
6-3. Limit Switch Assembly
Figure 6-1A. Brake, Spring, Motor
and Pinion Coupling Alignment
Figure 6-2. Limit Switch Wiring Diagram, 6415 Series AC Actuator
Figure 6-3. Limit Switch Assembly, 6415 Series AC Actuator
Figure 6-1B. Brake Spring, Motor
and Pinion Coupling Alignment
** Motor lead wire (red)
small terminal
* Motor lead wire
(blue) small terminal
NOTE
Duff-Norton’s PDC Series Control Box or
Two SPDT relays must be used to avoid
burning up the limit switches.

15
Notes

ECO 9-8865
SK-6415-300
PDF 01/17
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®
2017 © Yale Industrial Products, Inc., Duff-Norton Division
All rights reserved by Yale Industrial Products, Inc., Duff-Norton Division.
May not be copied in whole or in part.
Printed in the USA
P.O. Box 7010 • Charlotte, NC 28241-7010
Phone: [phone] • [phone]
Fax: [phone]
Email: [email protected]
www.duffnorton.com
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