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Workshop and Spare Parts Manual

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

Module 1G Hand / Auto Mechanism consists


of :-

Hand / Auto Lever


Cam
Spring
Stop Screw
O Rings

Also on sizes: 40, 70,90,91 and 95


Drive Key

Module 1G components
sizes 10,12,18,20,35

Module 1G components
sizes 40,70,90,91,95

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 1G Hand Auto Mechanism All mechanical sizes.
Publication 002-047-00 issue 06/13

It is not necessary to Removal of Actuator


remove the actuator from Valve Gearbox
from the valve or Take weight of the actuator on
gearbox to replace the the sling before removing the
hand auto lever. Pic 26 actuator to gearbox fixings.
Actuator should slide off
gearbox input shaft, ensure
Removing Actuator sling is holding the weight of the
from Valve if actuator at all times.
applicable.
WARNING
Before dismantling the actuator
isolate and disconnect incoming
electrical supply to actuator.
Remove and retain any
adaptors or reducers from the
threaded cable entries. Remove Drive Bush
Actuator sizes 12-95 can be
removed from their bases
leaving this to maintain the IQ sizes 10 to 95
valve position. In this case the Pic 27
base must be protected from Group ‘A’ Bases and
the environment.
Drive Bushes
(Types A, Z3 )
Alternatively, the actuator and
base can be removed as one To remove the thrust base from
piece. the actuator first remove the
stainless steel securing bolts,
Remove Actuator from retain these for refitting later.
Valve or Gearbox

WARNING Actuator Weights

ONLY PERSONS COMPETENT 10,12,18 = 31Kgs / 68lbs


BY VIRTUE OF THEIR TRAINING
AND EXPERIENCE SHOULD BE
20,25 = 54Kgs / 119lbs
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE
OR GEARBOX. 35 = 75Kgs / 165lbs

40, 70 = 145Kgs / 320lbs


AS THE ACTUATOR MAY BE
INSTALLED AT ANY ANGLE, 90, 95 = 160Kgs / 353lbs
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN
EACH INDIVIDUAL CASE. 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
pressure, close the valve fully. Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
Take the weight of the actuator A Type Thrust Base A Type Thrust Base
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
weight at all times.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes.
Publication 002-047-00 issue 06/13

IQ sizes 10 to 95 Top Handwheel


Assembly
Remove ‘B’ Type Base
Locate and remove the 3 fixing
Remove the Flange to Actuator screws locating the Cover Tube
Gearcase fixing bolts and lift off or Blanking Cap to the
the flange. handwheel assembly.

Remove Top Handwheel


Using the correct size circlip (If fitted)
pliers open the circlip and
remove, coupling can now be Locate and remove the fixing
knocked out from the screws locating the handwheel
handwheel end. hub assembly to the gearcase.

Oil Plugs - Drain Oil


Check that the condition of the
To drain the oil, remove one of ‘O’ Ring and the sealing face is
the two plugs situated in the satisfactory.
gearcase. Renew if necessary.
The oil may be drained from the Retain the assembly for refitting
gearcase after the top or side to the new Gearcase.
hand wheel assembly is
removed.

Remove Cover Tube or


Remove Side
Hub Sealing Cap.
(If fitted) Handwheel (If fitted)

The top or side handwheel Locate and remove the fixing


assembly should be fitted with screws locating the side
a Cover Tube or Sealing Cap handwheel hub assembly to the
to help prevent ingress of gearcase
moisture to the centre column
area. 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.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

Remove Hand Auto Remove move clutch


Lever spring, steel washer
and ‘o’ ring.
Sizes 10,12,18,20,25,35 Lift the spring steel washer and
‘o’ ring clear of the centre
Rotate Hand / Auto lever to column.
horizontal position to allow
removal of stop screw.
Locate and remove stop screw
threaded into shaft using 6 mm
hex key.

Remove clutch ring


Rotate Hand / Auto lever to
vertical position, the lever can and lifting yolk.
now be pulled out of the
gearcase.
Remove the clutch ring and
Note the position of the cam lifting yolk clear of the centre
and spring for reassembly column. Note the original
procedure. position for reassembly.

Remove the cam and spring


from the gearcase.

Sizes 40,70,90,91,95
Rotate Hand / Auto lever to
To remove Hand / Auto lever
horizontal position to allow
on sizes above IQ40 it is
removal of stop screw.
necessary to remove the
Locate and remove stop screw
clutch mechanism.
threaded into shaft using 6 mm
hex key.
To make the job safer a clutch
spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.

Rotate Hand / Auto lever to


vertical position, remove key
from shaft. The lever can now
Locate the ’o’ ring on top of the
be pulled out of the gearcase.
centre column, press down on
the steel washer beneath the
Note the position of the cam
’o’ ring and roll the ’o’ ring up
and spring for reassembly
the centre column.
procedure.
Take great care when
releasing the spring
Publication 002-047-00 issue 11/12
odule 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

When the spring and the cam


Reassemble Hand / are in the correct position push
Auto Assembly Using the lever fully into the gear
New Components. case.

Before fitting lever ensure that Rotate Hand / Auto lever to


the two ‘o’ ring seals are in horizontal position to allow
position on the shaft and that fitting of stop screw.
they are lightly greased. Tighten screw into shaft using 6
mm hex key.

Sizes 40,70,90,91,95
only
With the lever in the vertical
position insert partially into the Refit Clutch Ring
gearcase.
Before clutch ring is fitted
Slide the spring onto the shaft ensure the clutch lifting yolk is in
with the hook pointing down. the correct position located on
Engage the tail of the spring its pivot pin.
into the slot in the shaft.

With the spring in position slide Slide clutch ring over centre
the cam onto the end of the column ensuring splines are
shaft with the spring loaded engaged.
finger pointing down.
It may be necessary to rotate
the shaft slightly from side to
side to engage the cam into the
correct position.

Place the coil spring, steel


Sizes 40,70,90,91,95 washer with its chamfer
only uppermost onto the centre
column n in that order.
Rotate and position the lever to
insert the key into key slot in Press down on the steel washer
lever shaft. to compress the spring. Slide
the ’o’ ring over the centre
column and down into its grove.

To make the job safer a clutch


spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism 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 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

Group ’B’ Bases and


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

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 or
(Types A,Z3) Gearbox if required.
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 1G Hand Auto Mechanism All mechanical sizes

Publication 002-047-00 issue 06/13

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

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


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 Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
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.

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