A-2-H Actuator Positioners

Service Information

INSTALLATION and ADJUSTMENT

Mount the positioner firmly to the engine frame to

prevent relative motion between the operating lever
and the engine control arm. The positioner should be
installed with its operating lever in the same plane as
the engine control arm. Avoid interference with the
connecting link which could cause friction and
inaccuracy. Adjustable clevis and ball joint lever
attachments are available.
Full travel range of the positioner should be utilized
and the end travel of the lever attachment and the
engine control arm must match. The lever with
attachment is adjustable in length from 3 ¾ inches to
4 ½ inches (95mm to 114mm), which alters the end
travel from 1 7/8 inches to 2 ¼ inches (48mm to
57mm). For decreased lever travel, loosen jam nut
The A-2-H Actuator Positioner is a pneumatic positioner (100) and screw the attachment farther into the
used where accuracy is required and when the device to be operating lever. Tighten the jam nut to secure this
operated has low-force characteristics. Typical applications position. Lever travel can be increased by
are positioning the butterfly valve of carburetors and the unscrewing the attachment and then tightening the
control arm of diesel engine governors. jam nut.
If the end travel of the engine control arm exceeds
the maximum adjustment of the operating lever, the
normal procedure is to drill a hole in the control arm
at a point which has a travel range of two inches.
WARNING: INSTALLATION AND Fasten the connecting link to the new hole and
MOUNTING readjust the end travel of the control arm and
operating lever to match.
The user of these devices must conform to all applicable As assembled, the adjustable elements of the
electrical, mechanical, piping and other codes in the positioner are matched to provide zero lever travel
installation, operation or repair of these devices. with indicated preload pressure (usually 10 psi or 0.7
bar), and maximum lever travel with rated top
INSTALLATION! Do not attempt to install, operate or repair pressure (usually 60 psi or 4.1 bar).
these devices without proper training in the technique of The push rod travel is factory-set to correspond to
working on pneumatic or hydraulic systems and devices, rated top pressure. If the top pressure of the control
unless under trained supervision. valve is greater or less than that of the positioner, the
Compressed air and hydraulic systems contain high levels of travel of the control valve handle can be made to
stored energy. Do not attempt to connect, disconnect or match the travel of the operating lever by using the
repair these products when a system is under pressure. push rod travel adjusting screw (15).
Always exhaust or drain the pressure from a system before Two or more positioners can be matched to
performing any service work. Failure to do so can result in provide the same movement for a given change in air
serious personal injury. pressure. They can also be deliberately mismatched
to provide different lever travel to compensate for
MOUNTING! Devices should be mounted and positioned in inequalities in operating characteristics of the
such a manner that they cannot be accidentally operated. controlled device. If necessary to adjust for incorrect
initial pressure, remove or add shims (9 and 10) as

SM-900.4407
OPERATION MAINTENANCE
The Positioner has a usual pressure range of 10 to 60 psi (0.7 By removing only the cover (5), the diaphragm (6) can be
to 4.1 bar) within a temperature range of -40°F to 165°F (-40°C quickly replaced without removing the positioner from its
to 74°C). Pressure is supplied by a pressure control valve such mounting or disturbing the piping connection.
as the Rexroth CONTROLAIR® Valve or FLEXAIR® Valve. The When complete disassembly is required, clean all metal parts
pressure imposed on the diaphragm (6) is proportional to the with a nonflammable solvent and wash all rubber parts with
handle travel of the control valve. The movement of the soap and water. Rinse thoroughly and blow dry with a low-
positioner operating lever (14) is also proportional to this pressure air jet. Replace those parts which are damaged or
movement. Finally, the position of the controlled device is worn, giving particular attention to the condition of the
proportional to the handle travel of the control valve. diaphragm (6).
When supply pressure is reduced, the force of the spring (8) Reassemble the positioner using the exploded and assembly
against the push rod and spring seat assembly (7) returns the views as reference. No special tools are required. To maintain
lever to its new position corresponding to the value of air the same preload on the spring (8), shims (9 and 10) must be
pressure remaining. Supply pressure of 10 psi (0.7 bar) usually included. Apply Number 107 Lubriplate, or its equivalent, to all
provides idle position with 60 psi (4.1 bar) usually providing full grease fittings.
travel or full fuel position.
CONVERSION AND REPAIR KITS
Conversion Kits are available for A-2-H Actuator Positioners of previous designs. If the body castings are still in good condition,
these positioners should be converted to the current design at the earliest convenient maintenance period.
KIT Part Number R431005741 (Old Part Number P -061277-00000)
Will convert all A-2-H Actuator Positioners using lever Part Number 521100, prior to those listed in the Identity Schedule below.

REF. QTY DESCRIPTION

1 1 NUT, #10-32 Stop
2 1 BOLT, 1/4" Pivot
3 1 BEARING, 1/4" ID.
5 1 COVER, Diaphragm
6 1 DIAPHRAGM
7 1 PUSH ROD and SPRING SEAT ASSEMBLY, Complete
11 1 NUT, 1/4"-28 Stop
12 1 BOLT, 5/16" Pivot
13 1 BEARING, 5/16" ID.
14 1 LEVER

PART NUMBER PREVIOUS PART NO. DESCRIPTION

R431005743 P -061278-00000 Repair kit - minor kit (includes diaphragm & bearing)
R431006212 P -063286-00000 Repair kit - major kit (includes minor kit (above) and nuts & bolts

KIT PART NUMBER R431005999 (Old Part Number –062065-00000)

Will convert A-2-H Actuator Positioners listed as “Obsolete” in the Identity Schedule below to current design.
REF. QTY DESCRIPTION
5 1 COVER, Diaphragm
6 1 DIAPHRAGM
7 1 PUSH ROD and SPRING SEAT ASSEMBLY, Complete
IDENTITY SCHEDULE
PRESSURE WITH ACCESSORIES PART LESS ACCESSORIES ACCY. KIT
RANGE New P/N Old P/N New P/N Old P/N New P/N Old P/N
3-15 R431005217 P -059718-00011 R431005216 P -059718-00010 R431004143 P -057415-00000
10-60 R431004010 P -057159-00011 R431004009 P -057159-00010 R431004143 P -057415-00000
10-60 R431004011 P -057159-00012 -- -- R431004145 P -057416-00000
10-60 -- -- R431005745 *P -061289-00010 -- --

15-80 R431004529 P -058430-00011 R431004528 P -058430-00010 R431004143 P -057415-00000

35-90 R431003984 P -057086-00011 R431003983 P -057086-00010 R431004143 P -057415-00000

* Uses body (ref. 17a, page 3) with drain hole for mounting Positioner with lever in top position.
Page 2
 DESCRIPTION OF OPERATION
PARTS LIST
(In order of disassembly)
4 REF. QTY DESCRIPTION NEW P/N OLD P/N NOTES
1 1 NUT, #10-32 Stop See Repair Kits See Repair Kits
2 1 BOLT, 1/4" Pivot See Repair Kits See Repair Kits
3 1 BEARING, 1/4" ID. See Repair Kits See Repair Kits See note 1.
SCREW, 3/8"-16 x 1"
4 4 R431002619 P -050235-00003
5 Cap
5 1 COVER, Diaphragm See Repair Kits See Repair Kits
6 1 DIAPHRAGM See Repair Kits See Repair Kits See note 1.
PUSH ROD and
7 1 SPRING SEAT See Repair Kits See Repair Kits
6 ASSEMBLY, Complete
8A 1 SPRING, 3-15 psi R431003407 P -054642-00000
8B 1 SPRING, 10-60 psi R431000030 -523631-00000
8C 1 SPRING, 15-80 psi R431003004 P -052789-00000
SHIM, 0.031 Spring
9 1 R431002462 P -049904-00041 See note 2,3.
[not shown]
7 SHIM, 0.010 Spring
10 3 R431002463 P -049904-00042 See note 2.
[not shown]
11 1 NUT, 1/4-28 Stop See Repair Kits See Repair Kits
12 1 BOLT, 5/16" Pivot See Repair Kits See Repair Kits
13 1 BEARING, 5/16" ID. See Repair Kits See Repair Kits See note 1.
8 14 1 LEVER See Repair Kits See Repair Kits
15 1 SCREW, Adjusting R431005428 P -060256-00000
Drain hole Body NUT, Adjusting Screw
17 16 1 R431002450 P -049903-00038
17a only Lock
17 1 BODY R431003996 P -057111-00000
17A 1 BODY (with drain hole) R431003997 P -057111-00001 See note 4.

NOTES 1 Recommended spare parts to be retained in stock at all times.

2 Maximum quantity required; actual quantity installed at factory depends on spring
tolerances.
12 3 Positioners R431003983 ( Old P/N P -057086-00010) and R431003984
(Old P/N P -057086-00011) use six (6) of item 9 and do not require item 10.
13
2 4 * Uses body (ref. 17a, page 3) with drain hole for mounting Positioner with lever
3 in top position.
11
1 CLEVIS KIT P/N R431004143
100
16 (Old P/N P -057415-00000) 103
14 REF. QTY DESCRIPTION 104
100 1 NUT, 3/8"-24 Jam
15
102 1 NUT, Fulcrum Pin 102
103 1 PIN, Fulcrum
104 1 CLEVIS
BALL JOINT KIT P/N R431004145
(Old P/N P -057416-00000)
100 REF. QTY DESCRIPTION
100 1 NUT, 3/8"-24 Jam
101 101 1 BALL JOINT

Page 3
 OUTLINE DIMENSIONS

DRAIN HOLE PART NO OPERATING LEVER KIT

R431005745 ONLY CP. PART NO. R431004143

OPERATING LEVER KIT

CP. PART NO. R431004145

Page 4
 NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA INSTALLATION ! Do not attempt to install, operate or repair
Bosch Rexroth pneumatic devices are designed and tested for these devices without proper training in the technique of working
use with filtered, clean, dry, chemical free air at pressures and on pneumatic or hydraulic systems and devices, unless under
temperatures within the specified limits of the device. For use trained supervision. Compressed air and hydraulic systems
with media other than air or for human life support systems, contain high levels of stored energy. Do not attempt to connect,
Bosch Rexroth must be consulted. Hydraulic cylinders are disconnect or repair these products when a system is under
designed for operation with filtered, clean, petroleum based pressure. Always exhaust or drain the pressure from a system
hydraulic fluid; operation using fire-resistant or other special before performing any service work. Failure to do so can result
types of fluids may require special packing and seals. Consult in serious personal injury.
the factory. MOUNTING! Devices should be mounted and positioned in such
2. WARNING: MATERIAL COMPATIBILITY a manner that they cannot be accidentally operated.
Damage to product seals or other parts caused by the use of 4. WARNING: APPLICATION AND USE OF PRODUCTS
noncompatible lubricants, oil additives or synthetic lubricants in The possibility does exist for any device or accessory to fail to
the air system compressor or line lubrication devices voids operate properly through misuse, wear or malfunction. The user
Bosch Rexroth's warranty and can result in product failure or must consider these possibilities and should provide appropriate
other malfunction. See lubrication recommendations below. safe guards in the application or system design to prevent
AIR LINE LUBRICANTS! In service higher than 18 cycles per personal injury or property damage in the event of a malfunction.
minute or with continuous flow of air through the device, an air 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
line lubricator is recommended.* (Do not use line lubrication with When a device is disassembled for conversion to a different
vacuum products.) However, the lubricator must be maintained configuration, maintenance or repair, the device must be tested
since the oil will wash out the grease, and lack of lubrication will for leakage and proper operation after being reassembled and
greatly shorten the life expectancy. The oils used in the prior to installation.
lubricator must be compatible with the elastomers in the device. MAINTENANCE AND REPAIR! Maintenance periods should be
The elastomers are normally BUNA-N, NEOPRENE, VITON, scheduled in accordance with frequency of use and working
SILICONE and HYTREL. Bosch Rexroth recommends the use conditions. All Bosch Rexroth products should provide a
of only petroleum based oils without synthetic additives, and with minimum of 1,000,000 cycles of maintenance free service when
an aniline point between 180° F and 210° F. used and lubricated as recommended. However, these products
COMPRESSOR LUBRICANTS! All compressors (with the should be visually inspected for defects and given an "in system"
exception of special "oil free" units) pass oil mist or vapor from operating performance and leakage test once a year. Where
the internal crankcase lubricating system through to the devices require a major repair as a result of the one million
compressed air. Since even small amounts of non-compatible cycles, one year, or routine inspection, the device must be
lubricants can cause severe seal deterioration (which could disassembled, cleaned, inspected, parts replaced as required,
result in component and system failure) special care should be rebuilt and tested for leakage and proper operation prior to
taken in selecting compatible compressor lubricants. It is installation. See individual catalogs for specific cycle life
recommended that users review the National Fluid Power estimates.
Association "Recommended Guide Lines For Use Of Synthetic 6. PRODUCT CHANGES
Lubricants In Pneumatic Fluid Power Systems" (NFPA T1.9.2- Product changes including specifications, features, designs and
1978). availability are subject to change at any time without notice. For
3. WARNING: INSTALLATION AND MOUNTING critical dimensions or specifications, contact factory.
The user of these devices must conform to all applicable *Many Bosch Rexroth pneumatic valves and cylinders can
electrical, mechanical, piping and other codes in the installation, operate with or without air line lubrication; see individual sales
operation or repair of these devices. catalogs for details.

LIMITATIONS OF WARRANTIES & REMEDIES

Bosch Rexroth warrants its products sold by it to be free from defects in material and workmanship to the following:
For twelve months after shipment Bosch Rexroth will repair or replace (F.O.B. our works), at its option, any equipment which under normal
conditions of use and service proves to be defective in material or workmanship at no charge to the purchaser. No charge will be made for labor
with respect to defects covered by this Warranty, provided that the work is done by Bosch Rexroth or any of its authorized service facilities.
However, this Warranty does not cover expenses incurred in the removal and reinstallation of any product, nor any downtime incurred, whether
or not proved defective.
All repairs and replacement parts provided under this Warranty policy will assume the identity, for warranty purposes, of the part replaced, and
the warranty on such replacement parts will expire when the warranty on the original part would have expired. Claims must be submitted within
thirty days of the failure or be subject to rejection.
This Warranty is not transferable beyond the first using purchaser. Specifically, excluded from this Warranty are failures caused by misuse,
neglect, abuse, improper operation or filtration, extreme temperatures, or unauthorized service or parts. This Warranty also excludes the use of
lubricants, fluids or air line additives that are not compatible with seals or diaphragms used in the products. This Warranty sets out the
purchaser's exclusive remedies with respect to products covered by it, whether for negligence or otherwise. Neither, Bosch Rexroth nor any of
its affiliates will be liable for consequential or incidental damages or other losses or expenses incurred by reason of the use or sale of such
products. Our liability (except as to title) arising out of the sale, use or operation of any product or parts, whether on warranty, contract or
negligence (including claims for consequential or incidental damage) shall not in any event exceed the cost of replacing the defective products and,
upon expiration of the warranted period as herein provided, all such liability is terminated. THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, WHETHER FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE.
No attempt to alter, amend or extend this Warranty shall be effective unless authorized in writing by an officer of Bosch Rexroth Corporation.
Bosch Rexroth reserves the right to discontinue manufacture of any product, or change product materials, design or specifications
without notice.

Page 5
 Bosch Rexroth Corporation
Pneumatics
1953 Mercer Road
Lexington, KY 40511-1021
Telephone (859) 254-8031
Facsimile (859) 254-4188
[email protected]
www.boschrexroth-us.com/brp

International offices: Factory Automation North American offices: Bosch Rexroth Canada
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Industrial Hydraulics CP 07700 Mexico, D.F.
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United Kingdom Facsimile (860) 844-8595 Bosch Rexroth Corporation
Linear Motion and Assembly The data specified herein only serves to
North America: Bosch Rexroth Corporation Technologies describe the product. No statements
Canada United States 2315 City Line Road 816 E. Third Street concerning a certain condition or suitability
Mexico Bethlehem, PA 18017-2131 Buchanan, MI 49107 for a certain application can be derived
Telephone (610) 694-8300 Telephone (269) 695-0151 from our information. The given information
South America: Facsimile (610) 694-8467 Facsimile (269) 695-5363 does not release the user from obligation
Argentina Venezuela of own judgment and verification. It must
Brazil Southeast 14001 South Lakes Drive be remembered that our products are
Bosch Rexroth Corporation Charlotte, NC 28273 subject to a natural process of wear and
14001 South Lake Drive Telephone (800) 438-5983 aging. ©This document, as well as the
Charlotte, NC 28273-5544 Facsimile (704) 583-0523 data, specifications and other information
Telephone (704) 583-4338 set forth in it, are the exclusive property of
Facsimile (704) 583-0523 Bosch Rexroth Corporation Bosch Rexroth Corp. Without their con-
Mobile Hydraulics sent it may not be reproduced or given to
West 145 Southchase Boulevard third parties.
Bosch Rexroth Corporation Fountain Inn, SC 29644-9018
11 Goddard Telephone (864)967-2777
Irvine, CA 92618-4600 Facsimile (864)962-5338
Telephone (949) 450-2777
Facsimile (949) 450-2790

Printed in the United States

SM-900.4407
©2008 Bosch Rexroth Corporation (Supercedes B3-44.07)
December 2008