OVERHAUL INSTRUCTIONS

Rotac Model S-7.40x2.50

Bill of Material 26-10-7632

For further information contact:

Micromatic
Micromatic, A Textron Company.
525 Berne Street
Berne, Indiana 46711
Phone: 260/589-2136 Fax: 260/589-8966

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ACTUATOR DISASSEMBLY, INSPECTION AND ASSEMBLY

INTRODUCTION
These instructions provide overhaul instructions and parts list for the S-7.40x2.50-1V-DE-K-FT SPEC Rotac
Rotary Actuator.
Do not attempt to overhaul an actuator without having a seal kit on hand. Refer to the parts list, Figure 6, for
information regarding seal kits. The exploded view drawing, figures 6 & 7, should be used for reference in following
the overhaul instructions.

DISASSEMBLY
Read the special instructions below before proceeding. Reference figures 6 & 7 for relative part location(s).
1. Clean exterior of unit as clean as possible. This will help assure that any material found in the unit is a
result of wear, system contamination or damage. A more accurate evaluation of the unit and operation
system is thus obtained.
2. Remove all burrs from the shaft (12) extension.
3. Before disassembly, the body (10) heads (8,11) and shaft (12) should be marked in order to return parts
to their relative positions during assembly.
4. Do not hold a rotary actuator in a vise unless special precautions are taken to avoid marring or distorting the
body or ends. The preferred method of holding the actuator during disassembly is mounting on a holding
fixture, which simulates normal actuator mounting.
5. After removing head screws from both heads (8,11), strike end of shaft with plastic mallet or aluminum bar
stock, and allow the shaft to push the head off. These units have threaded holes in the head that will
assist you to separate the head from the body. DO NOT PRY HEADS OFF!!! Damage will occur to body
or heads.
6. Pull the shaft out, with a straight even pull, being careful that the shaft (12) vane does not fall and nick the
body (10).
IMPORTANT: Do not allow the shaft (12) to cock as this may break the sharp edges on the body causing
internal leakage during operation.
7. Remove all seals and inspect for cuts, nicks, or any other unusual conditions of the seal. (Compare to
new seal kit).
INSPECTION/EVALUATION
1. Examine oil residue inside actuator. This may give a clue as to why any damage has occurred.
A. Dirty or gritty oil will cause scoring of internal surfaces.
B. Varnish on internal parts can be a sign of oil in system running too hot.
C. Metal particles - Metal chips may be found from valve spools, actuator internal parts and other metal
components in the system.
The appearance of the above, will require total flushing and cleaning of the entire system.
2. Wash all parts thoroughly and examine for defects.
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A. Shaft (Figure 1)
1. Examine the vane for cracks at
"A" diameter, keyways, and
any other areas where stress
may be applied.
a. Spot check by Magnaflux
can be used to check for
cracks.
Three different materials
are needed and must be
applied in order:
SKC-S Cleaner
SKL-HF/SKL-S Penetrant
SKD-S Developer
FOLLOW DIRECTIONS
ON BACK OF THE CANS CAREFULLY
b. Keyways that are widened
Figure 1 Shaft Definitions
may fit loosely in coupling.
This problem will only get
worse and eventually cause shaft to break. Cause - poor fitting coupling. Too soft keys.
c. Scoring on "A" (major) diameter. See figure 1.
Any scratch .010 or more deep indicates replacement.
d. Scoring or galling on shaft journal. See figure 1.
This problem can be repaired with hard chrome, however, many critical dimensions must be
held - this type of repair should be performed by actuator factory.
e. Scoring or galling on end of "A" (major) diameter. See figure 1.
This is another problem that can be repaired; however, it is recommended that this type repair
be performed by actuator factory.
B. Body
1. Any light scoring can be polished out with 400-grit emery cloth or it's equivalent. Scoring of .010 or
more deep indicates replacement of this part. When pressurized, the body will expand and contract.
For this reason, plating or sleeving is not recommended by the factory for repair.
2. Cracks may be found across the dowel holes, screw holes or ports. This indicates replacement.
3. Dowel holes may be elongated or out of round. These holes may be drilled oversize or rebushed,
however, the proper size and location of the dowel hole must be known to accomplish this repair.
C. Heads - See figure 2.
1. Bushing /bushing bore-(actuator per B/M 26-10-7632 has no bushing) If the bearing is worn or scored,
it must be replaced and machined to properly fit the shaft. Bearing-less heads may be machined and
bushing 26-04-2229 installed. Additionally, the bearing must be machined flush with the bottom of the
hub seal counterbore if it protrudes. Because of the listed machining operations, it is suggested that
this repair be done at the factory. However, the required operations are listed below.

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Replacement of bushing must be done in the following steps:

i.

Old bushings must be machined out of the ends. If this procedure is used, use care to avoid
damaging the ends.
ii. Freeze new bushing to -100 degrees F.
iii. Press in with proper tonnage and insure bushing is firm against shoulder.
iv. The ID must be machined after installation to match the shaft diameter, plus 0.001-inch to
0.003-inches clearance, and concentric with the shaft relief diameter & hub seal counterbore
with 0.001-inchT.I.R. (See figure 2).

Figure 2
2. Scoring on face of head must be repaired. Possible causes are:
a. gritty particles in the oil
b. Axial load on shaft.
3. Minor scoring can be polished out with emery cloth.
4. Cracks in head are usually around bolt circle or dowel pattern and if this occurs, replacement of the
part is necessary.
D. Seals - It is recommended that all seals be replaced.
1. Cut or shaved seal is usually done during assembly.
This can occur in a number of different ways. Refer to assembly instruction for proper assembly.

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SEAL REPLACEMENT AND ASSEMBLY

The assembly area must be clean and free from all dirt, dust, or other harmful material. A plastic or metal
covered workbench is the best. Parts should be recleaned if necessary. A small pliable brush should be used to
clean seal grooves, dowel holes, screw holes and other hard-to-get-at areas. Remove all burrs that may be on
any part. Do not break corners on shaft "A" diameter or body. These sharp edges are important to the operation
and function of the actuator.

Tools
During the assembly of the unit, the seals need to
be protected. Assembly tools are required to install
seal kits. The tools are; a dummy head - to hold
the shoe seal during installation, a shoe seal
protector, a vane seal protector, and a shaft seal
protector. Reference table 3 and figure 3.
Use a lubricant on all seals and internal parts that is
compatible with the driving fluid used. DS-ES
Lubriplate by Fiske Brothers is used at the factory.
Petroleum jelly is also compatible in most hydraulic
systems.

Assembly- reference Figures 6 & 7.

SK-4057
SK-3225
*SK4133

A. Place body (10) on a flat surface. Put the head

dowels into the body for the dummy head.
Attach the dummy head so that it is properly
seated. Turn the body and dummy head over
so that the head is on the flat surface.
B. Install the shoe seal cushion (1) and shoe seal
cap (2) into the body (10).
C. Lubricate the shoe seal cap (2) and the ID of
SK-3224
the body (10)
D. Insert the vane seal cushion (15) and "C"
shaped shaft vane seal cap (16) in vane of the
shaft (12). Lubricate to hold the seals in
position. Lubricate the "A" diameter of the shaft
(see figure 1). Use care to avoid nicking or
cutting the vane seal. All seal corners must
remain sharp.
E. Place the vane seal protector on the body and
SK-3223
assure that it is properly seated. Place the
shoe seal protector over the shaft extension
and place this assembly into the dummy head.
Rotate the shaft approximately 90o from the
shoe position. Slide the shaft into the body until
the vane is fully installed. Remove the vane
seal protector and the shoe seal protector.
F. Install shaft seal cushion (4) and shaft seal cap
(3) into the head (8). Smooth out ripples or
Figure 3 Assembly Tools
wrinkles in the installed shaft seal cap (3).
Place wavy seal spring (5), hub seal ring (6),
and hub seal (7) into the head (8). Insure that hub seal (7) is free to move axially.
G. Place head seal O-ring (9) into the groove in the head (8).
H. Lubricate all seals and internal parts with grease sufficient to maintain the seals in position when the head is
inverted and installed on the body (10)
I. Install the shaft seal protector into the head (8) and dummy half keys (keys not needed for -7632 actuator) into
the shaft (See figure 3). Invert the head (8) and carefully slide it down over the shaft. Do not hammer on the
head or allow the hub seal to become dislodged from its cavity as the head is mated to the body. Install two
screws 180 apart and tighten the screws to pull the head (8) onto the body (10).
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J. Install the head dowels (14) into the head and the remainder of the screws through the head (8) and into the
body (10).
K. Turn the assembly over and remove the dummy head.
L. Install shaft seal cushion (4) and shaft seal cap (3) into the head (11). Smooth out ripples or wrinkles in the
installed shaft seal cap (3). Place wavy seal spring (5), hub seal ring (6), and hub seal (7) into the head (11).
Insure that hub seal (7) is free to move axially.
M. Place head seal O-ring (9) into the groove in the head (11).
N. Lubricate all seals and internal parts with grease, sufficient to maintain the seals in position when the head (11)
is inverted and installed on the body (10)
O. Install the shaft seal protector into the head (11) and dummy half keys (keys not needed for -7632 actuator)
into the shaft (See figure 3). Invert the head (11) and carefully slide it down over the shaft. Do not hammer
on the head or allow the hub seal to become dislodged from its cavity as the head is mated to the body.
Install two screws 180 apart and tighten the screws to pull the head (11) onto the body (10).
P. Place the shaft seal protector into the head (11) (See figure 3). Invert the head (11) and carefully slide it down
over the shaft. Do not hammer on the head or allow the hub seal to become dislodged from its cavity as the
head is mated to the body. If necessary, install two screws 180 apart and tighten the screws to pull the head
(11) onto the body (10).
Q. Install the head dowels (14) into the head and the remainder of the screws, through the head (11) and into the
body (10).
R. Torque all head screws (13) per table 1, torque specifications.
Factory built actuators are then tested for internal by-pass leakage and breakaway pressure. See chart in
table 2. Actuator should be cycled 10-20 times before beginning the tests.

TABLE 1 TORQUE CHART

MODEL

SCREW SIZE

S 7.40x2.50

7/16 14

TORQUE
60 Ft. Lbs. Greased

TABLE 2 BREAKAWAY & LEAKAGE CHART

MODEL

BREAKAWAY PRESSURE

S 7.40x2.50

50 PSI

INTERNAL BY-PASS LEAKAGE

per minute
30 cu. in. @ 3000 PSI

INTERNAL BY-PASS LEAKAGE: Leakage checks to be made at pressure listed. The fluid is measured out the
exhaust port of the actuator. Pressure to be maintained at psi listed for one (1) full minute before check is
started. The unit is tested in both directions.
BREAKAWAY PRESSURE: an internal pressure, as listed, must accomplish rotation of an actuator shaft through
the full stroke. The unit is tested in both directions.
EXTERNAL LEAKAGE: there should be no external leakage from the unit.

TABLE 3 Assembly Tools

TOOL
SK-3223
SK-3224
SK-3225
SK-4057
*SK-4133

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TOOL NUMBER
DUMMY HEAD
VANE SEAL PROTECTOR
SHOE SEAL PROTECTOR
SHAFT SEAL PROTECTOR
SHAFT SEAL PROTECTOR

TABLE 4 Seal Kit

MODEL

SEAL KIT NUMBER

S 7.40x2.50

26-90-7577

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FIGURE 6 - Parts View

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FIGURE 7 - Parts View

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TABLE 5
Trouble Shooting Guide
TROUBLE
External Leakage at
Shaft

PROBABLE CAUSE

REMEDY

Defective shaft seal(s) (3) or O-ring(s) (4).

Replace defective parts.

Shaft (12) scored or worn. Bushings (17) defective.

Repair shaft or replace

defective part.

External Leakage at
Joint Between
Head (8,11) and
Body (10)

Defective O-rings (9), or damaged sealing surface on head

(8,11) or body (10). Improper torque on the head screws(13).

Replace defective O-ring.

Repair or replace damaged
parts.

Excessive Internal
Leakage

Defective shoe seal (1),), shoe seal cushion (2) vane seal
cushion(15)and/or vane seal (16)

Replace defective parts.

Defective hub seal (7), hub seal ring (6), or hub seal spring (5).

Replace defective parts.

Worn or scratched end faces on head (8,11) or in body (10).

Repair or replace.

Worn or scratched ID of body (10).

Repair or replace.

Worn bushing(s) (17).

Replace bushings.

Head screws (13) not tightened sufficiently.

Tighten to recommended
torque.

"C" style vane seal not seated properly (applicable to units

immediately after overhaul only).

Operate through full cycles for

a few minutes to attempt to
seat seals.

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