Workshop and Spare Parts Manual

IQ Mk 3 Range Actuators
Module 1B All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1B Centre Column Module consists

of :-

Centre Column
Worm Gear
Clutch Assembly
Seals
Bearings
Worm Shaft

Module 1B Centre Column assembly and Worm Shaft

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
 Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Removing Actuator Removal of Actuator

from Valve from Valve Gearbox

WARNING Take weight of the actuator on

Before dismantling the actuator the sling before removing the
isolate and disconnect incoming Pic 26 actuator to gearbox fixings.
electrical supply to actuator. Actuator should slide off
Remove and retain any gearbox input shaft, ensure
adaptors or reducers from the sling is holding the weight of the
threaded cable entries. actuator at all times.
Actuator sizes 12-95 can be
removed from their bases
leaving this to maintain the
valve position. In this case the
base must be protected from
the environment.

Alternatively, the actuator and Remove Drive Bush

base can be removed as one
piece.
IQ sizes 10 to 95
Pic 27 Group ‘A’ Bases and
Remove Actuator from
Valve or Gearbox Drive Bushes
(Types A, Z3 )
WARNING
To remove the thrust base from
ONLY PERSONS COMPETENT the actuator first remove the
BY VIRTUE OF THEIR TRAINING stainless steel securing bolts,
AND EXPERIENCE SHOULD BE retain these for refitting later.
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE Actuator Weights
OR GEARBOX.
10,12,18 = 31Kgs / 68lbs
AS THE ACTUATOR MAY BE
INSTALLED AT ANY ANGLE, 20,25 = 54Kgs / 119lbs
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN 35 = 75Kgs / 165lbs
EACH INDIVIDUAL CASE.
40, 70 = 145Kgs / 320lbs

90, 95 = 160Kgs / 353lbs

91 = 150Kgs / 331lbs

Actuator Direct
Mounted onto Rising
Stem Valves
WARNING
Ensure pressure is removed
Pic 75
from pipeline, move valve
‘open’ a short distance to
eliminate any locked in
Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
pressure, close the valve fully.
A Type Thrust Base A Type Thrust Base
Take the weight of the actuator
on the sling before removing
the actuator to valve fixings,
wind the handwheel in the
‘close’ direction when actuator
will move up the valve stem,
ensure sling is holding the

Module 1B Centre Column All mechanical sizes
IQ sizes 10 to 95
Remove ‘B’ Type Base
Remove the Flange to Actuator
Gearcase fixing bolts and lift off
the flange.
Using the correct size circlip
pliers open the circlip and
remove, coupling can now be
knocked out from the
handwheel end.
Oil Plugs - Drain Oil
To drain the oil, remove one of
the two plugs situated in the
gearcase.
The oil may be drained from the
gearcase after the top or side
hand wheel assembly is
removed.
Drain/fill plugs
Remove Cover Tube or
Hub Sealing Cap.
(If fitted)
The top or side handwheel
assembly should be fitted with
a Cover Tube or Sealing Cap
to help prevent ingress of
moisture to the centre column
area.
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Publication 002-047-00 issue 06/13
Top Handwheel
Assembly
Locate and remove the 3 fixing
screws locating the Cover Tube
or Blanking Cap to the
handwheel assembly.
Remove Top Handwheel
(If fitted)
Locate and remove the fixing
screws locating the handwheel
hub assembly to the gearcase.
Check that the condition of the
‘O’ Ring and the sealing face is
satisfactory.
Renew if necessary.
Retain the assembly for refitting
to the new Gearcase.
Remove Side
Handwheel (If fitted)
Locate and remove the fixing
screws locating the side
handwheel hub assembly to the
gearcase
Check that the condition of the
‘O’ Ring and the sealing face is
satisfactory.
Renew if necessary.
Retain the assembly for refitting
to the new Gearcase.

Module 1B Centre Column
IQ, IQS, IQML 10, 12, 18, 20, 25, 35 Only
Remove Motor Stator
Before removing motor stator
cover mark its position relative
to the top of the gearcase.
Remove and retain the four cap
head screws, slide the stator off
the gearcase.
Be careful not to damage
Motor and Torque Transducer
wiring during removal.
Do not mislay the coil spring at
the outboard end of the rotor
shaft. Retain for refitting.
Motor Rotor
Using an allen key (hex wrench)
and a hex socket remove and
retain the bolt and nut securing
the rotor shaft to the worm
shaft, slide the rotor shaft off
and retain in a safe place for
refitting.
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Publication 002-047-00 issue 06/13
Disconnect Torque
Transducer
Using an Allen Wrench remove
the 2 screws securing the plastic
mounting bracket to the torque
transducer thrust plate.
Disconnect the loom connected
to the torque transducer.
Explosionproof Units
only
(CENELEC/FM/CSA)
In explosionproof units there is a
black plastic cable retainer
clipped onto the thrust retaining
plate. This must be retained for
refitting.
Explosion Proof Units Only.
Explosion-proof wiring looms
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored or
damaged in any way.
Remove Thrust Plate
Remove the 3 fixings locating the
thrust plate to the gearcase. And
remove plate

Module 1B Centre Column All mechanical sizes
IQ40, 70, 90, 91, 95 Only
Remove Motor Stator
WARNING
It is advisable to support the
weight of the motor as it
could weigh up to 70Kg
(154lbs).
Before removing motor stator
mark its position relative to the
gearcase.
Remove and retain the four cap
head screws, slide the stator
out of the gearcase onto the
work surface.
Be careful not to damage
Motor and Torque Transducer
wiring during removal.
Do not mislay the coil spring at
the outboard end of the rotor
shaft. Retain for refitting.
Motor Rotor
Using a 36mm wrench remove
hex nut on end of rotor shaft.
Now remove locking washers
and taper coupling.
Note
Carefully remove drive key from
end of rotor shaft.
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Publication 002-047-00 issue 06/13
Slide rotor of shaft and retain all
components for refitting.
WT Units Only
Remove the Motor and Torque
Transducer wiring loom and
retain for refitting.
Explosionproof Units
only
(CENELEC/FM/CSA)
In explosionproof units there is
a black plastic cable retainer
clipped onto the thrust retaining
plate. This must be retained for
refitting.
Remove the 6 fixings locating
the thrust plate to the gearcase
to allow removal of the Motor
and Torque transducer wiring
loom and retain for refitting.
Explosion Proof Units Only.
Explosion-proof wiring looms
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored
or damaged in any way.
Remove Thrust Ring
Undo 6 hex head bolts and
remove thrust ring.

Module 1B Centre Column All mechanical sizes
Remove Torque
Transducer and Worm
Shaft
IQ Sizes 10, 12, 18, 20,
25, 35 Only
Holding end of motor shaft
withdraw torque transducer,
and bronze bush.
The torque transducer and
bronze bush can now be
removed from the worm shaft.
Retain in safe place for refitting.
Do not dismantle torque
transducer assembly.
IQ Sizes 40, 70, 90, 91,
95 Only
Holding end of motor shaft
withdraw the shaft and torque
transducer assembly.
Remove the Torque
Transducer from the
Wormshaft
First remove the 10 mm
diameter drive pin from the
worm shaft.
To remove pin secure shaft in
soft jaw vice and drive out with
parallel pin punch.
Unscrew the hex locking screw,
this will allow the torque
transducer and bearing to be
removed and retained in safe
place for refitting.
Do not dismantle torque
transducer assembly.
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Remove Centre Column
Assembly
IQ Sizes 10, 12, 18 Only
Locate and remove 2 fixing
screws holding centre column
base plate into gearcase.
Withdraw centre column
assembly from gearcase.
Ensure the clutch lifting cam is
disengaged or this will prevent
the assembly from withdrawing.
IQ Sizes 20, 25, 40, 70,
90, 91, 95 Only
Locate and remove 4 fixing
screws holding centre column
base plate into gearcase.
Ensure the clutch lifting cam is
disengaged or this will prevent
the assembly from withdrawing.
Withdraw centre column
assembly from gearcase.
It is advisable to use a lifting
device for safe removal of this
module.
 Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

The lower seal can now be

removed with a suitable tool. Using 6mm Allen key (hex head)
locate and tighten 2 screws
holding cast plate into gearbox.

Reassembly of IQ Sizes 20, 25, 40, 70,

Actuator using new
components as
supplied in Module 1B
To aid reassembly and prevent
damage to new seals and
bearings, assembly tools can
be purchased via your local
agent or direct from Rotork.
90, 91 Only
Lightly grease the lower end of
centre column before fitting into
gearcase. Locate it through base
seal and push into gearcase until
cast plate sits on the mounting
face, only hand force should be
necessary.

It is advisable to use a lifting

device for safe fitting of this
module.
Fit Lower Seal

Press lower seal into the Using 6mm Allen key (hex head)
gearcase from the inside, locate and tighten screws hold-
ensure seal and castings are ing cast plate into gearbox.
clean and greased and that the
lips are positioned facing
towards the inside of the
gearcase.

Refit Centre Column

Assembly

IQ Sizes 10, 12, 18 Only

Lightly grease the lower end of

centre column before fitting into
gearcase. Locate it through
base seal and push into
gearcase until cast plate sits on
the mounting face, only hand
force should be necessary.
 Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Refit Torque
Transducer and Worm
Shaft

IQ Sizes 10, 12, 18, 20,

25, 35 Only
The torque transducer and
bronze bush can now be fitted
from the new worm shaft.

Holding end of motor shaft refit

torque transducer, and bronze
bush.

NOTE

Locate the torque transducer

onto the dowel pin in the
gearcase. Only a light pressure
on the wormshaft will be
needed to locate the complete
assembly.

IQ Sizes 40, 70, 90, 91,

95 Only

The torque transducer, bearing

and Hex locking nut can now be
fitted from the new worm shaft.

Fit the 10 mm diameter drive

pin into the worm shaft.

To fit pin secure shaft in a soft

jaw vice and drive into position
with parallel pin punch.

Holding end of motor shaft refit

torque transducer and bronze
bush.

NOTE
Locate the torque transducer
onto the dowel pin in the
gearcase. Only a light pressure
on the wormshaft will be
needed to locate the complete
assembly.
 Publication 002-047-00 issue 11/12
Module 1B Centre Column
IQ, IQS, IQM, IQML 10, 12, 18, 20, 25 & 35 Only
Publication 002-047-00 issue 06/13

Refit Motor
Fit coil spring onto outboard end
Feed the motor cables through of rotor shaft.
into the electronics
compartment.

Explosionproof Units
Only
(CENELEC/FM/CSA) Fit Motor Stator to
Remove the 3 fixings locating Gearcase
the thrust plate to the gearcase,
this will allow the steel transfer
bush and motor loom to be Before fitting motor ensure the
fitted. Refit the thrust plate. spigotted joint is clean and
lightly greased and that the ’O’
Explosion-proof wiring looms ring seal is serviceable.
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored
or damaged in any way.
WT Only
Explosionproof Units
Only Slide stator over rotor shaft, do
not damage the windings, feed
The black plastic cable retainer the motor cables into the
can now be clicked into position electrical compartment.
on the flange, ensure that the
cut-out aligns with the motor
cable.

Reconnect the torque
transducer loom . Using an
Allen key wrench refit the
plastic mounting bracket onto
the transducer thrust plate.
Fit Motor Rotor
Explosionproof Only
On these units the motor loom
remains in the motor
compartment, to prevent it being
damaged it must be positioned
correctly in its plastic retainer as
follows:-
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
the gearbox. Screws to be
tightened to 16.5Nm (12lb/ft).

Slide the rotor shaft onto the

end of the wormshaft, align the
bolt hole and fit shouldered bolt
and nyloc nut, tighten to 6.8Nm.
 Publication 002-047-00 issue 11/12
Module 1B Centre Column
IQ 40, 70, 90, 91 & 95 Only
Publication 002-047-00 issue 06/13

Refit Motor Fit coil spring onto outboard end

of rotor shaft.
Feed the motor cables through
into the electronics
compartment.

Explosionproof Units
Only
(CENELEC/FM/CSA)
Remove the 6 fixings locating
the thrust plate to the gearcase,
this will allow the steel transfer
bush and motor loom to be
fitted. Refit the thrust plate.
Fit Motor Stator to
Explosion-proof wiring looms Gearcase
are fitted with a steel transfer
bush, this is a certified flame Before fitting motor ensure the
path and must not be scored spigotted joint is clean and
or damaged in any way. lightly greased and that the ’O’
ring seal is serviceable.
Explosionproof Units
Only
The black plastic cable retainer
can now be clicked into position
on the flange, ensure that the
cut-out aligns with the motor
cable.

WT Only

Reconnect the torque Slide stator over rotor shaft, do

transducer loom . Using an
Allen key wrench refit the
plastic mounting bracket onto
the transducer thrust plate.
Fit Motor Rotor
Slide the original rotor onto the
wormshaft, ensure the slot on
the in-board end engages with
the locating pin.
The components are fitted to
the wormshaft in the following
order:-
Rotor
Key
Cone
Locking Washers
Lock Nut
Coil Spring.
not damage the windings, feed
the motor cables into the
electrical compartment.
Explosionproof Only
On these units the motor loom
remains in the motor
compartment, to prevent it being
damaged it must be positioned
correctly in its plastic retainer as
follows:-
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
the gearbox. Screws to be
tightened to 16.5Nm (12lb/ft).
 Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Fill Gearbox With Oil

Before fitting hand drive fill

gearcase with fresh oil through
the hand drive aperture, ensure
all oil drain plugs are sealed,
that the sliding clutch coupling
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3

Refit Top Handwheel

Check the condition of the ‘O’

ring is serviceable. And sealing
face is satisfactory.

Carefully refit handwheel

assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm

Allen (hex wrench).
 Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Refit side handwheel Group ’B’ Bases and

(if fitted)
Check the condition of the ‘O’
ring is serviceable and sealing
face is satisfactory.
Carefully refit side handwheel
assembly ensuring ‘O’ ring is in
position .
Bushes
Using the correct size circlip
pliers open the circlip and
relocate the drive bush onto the
centre column ensuring the clip
is located in the slot.

Tighten down fixings with 6mm

Allen key (hex wrench)

Refit Cover Tube or

Hub sealing Cap Refit flange adaptor onto
gearcase and secure hex bolts.
The top or side handwheel
should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the
centre column area.

Torque values fitting bases

Ensure the ’O’ ring is in position
and serviceable then refit cover
tube or cap. Locate screws and
tighten using Allen key ( hex
wrench)

Refitting Drive Bush

Group ‘A’ Bases and

Drive Bushes. Refit Actuator to Valve
(Types A,Z3) or Gearbox.
If the actuator was originally
removed from the valve
together with its base and drive
coupling then these must be
refitted onto the gearcase.

Carefully align the centre

column drive dogs into drive
coupling and tighten fixings.
Module 1B Centre Column All mechanical sizes

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing
battery and using the strap
Whilst the actuator is down for
provided pull out of its plastic
maintenance it is recommended
holder.
that its battery be changed.
The battery as fitted by Rotork
Fit new battery into strap and
is generally a PP3 9 volt
push into its holder,
Ultralife Lithium cell.
reconnect.
For Hazardous area certified
Refit and tighten threaded
units ONLY approved battery
plug after lightly greasing
types must be used.
thread and checking sealing
‘O’ ring is serviceable.
See Below for Approved Battery
Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a Recommission the actuator
lithium manganese dioxide battery as stated in Table 1 BELOW. using Publication
Pub 002-039-00 and the
For FM and CSA certified enclosures use an Ultralife U9VL lithium Rotork Bluetooth Setting Tool.
manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium

manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail

ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P

ATEX/IEC Ex Rotork Part Numbers 95-462 or

Low/High Temp 95-614

The battery is situated in its

own compartment located in the
gearcase.

Using an 8mm allen key (hex

wrench) remove the access
plug.